Gleason's Approach

Profile: Lawler Gear Corporation Q&A: Greg Allen Company Gleason’s Approach toto High-Tech Plating Custom Workholding by Drewco

A MEDIA SOLUTIONS PUBLICATION JULY 2003

JULY 2003 A MEDIA SOLUTIONS PUBLICATION

6 industryNEWS New products, trends and developments in the gear industry 13 terryMcDONALD — Safety Matters Common-sense commentary on how easy—and important—it is to departments stay sharp on the job when it comes to safety.

features 14 Company Profile By Russ Willcutt pg. 14 Lawler Gear Corporation From a four-man operation to a thriving business, Lawler Gear provides an interesting mix of services. 18 Custom Solutions for Workholding Challenges By Matt Peterson Since every customer’s needs are different, this company places a premium on designing custom-tailored workholding solutions. pg. 18 26 Reinventing the Wheels By Michael Hayes Years in the making—and less than two years out of the gates—Gleason Cutting Tools’ new plating facility is a marvel of high-tech productivity. 40 Q&A — Greg Allen Greg Allen is a real world traveler, constantly combing the globe pg. 26 for premium parts to import into the U.S. marketplace. special advertising sections 33 MACHINES 36 MARKETPLACE 39 INDEX OF ADVERTISERS

gearsolutionsonline.com • JULY 2003 • GEAR SOLUTIONS 3 From the Publisher

Hello, and welcome to the July issue of Gear Solutions magazine. This time around we’ve turned our attention to tooling and workholding, and we hope you’ll enjoy reading the informative articles we’ve compiled on the subject. HWe’re also quite pleased about the caliber of the subjects themselves— Gleason Cutting Tools and the Drewco Corporation, as well as additional features on the Lawler Gear Corporation and the Greg Allen Company. We feel that the Gleason article is particularly powerful, as it features Published by the company’s new superabrasives wheel plating facility in Loves Park, Media Solutions, Inc. Illinois. After years of R&D—and a substantial investment on the compa- P.O. Box 383185 ny’s part—Gleason Cutting Tools has achieved amazing tolerances, and Birmingham, AL 35238 1-800-366-2185 Michael Hayes’ article describes how they have gone about achieving their goals. We found the words of Jay Werner, Gleason’s superabrasives plating manager, to be particularly insightful, and we wish him—and the company, David C. Cooper itself—the best of luck as they move forward on this very exciting project. PUBLISHER As for the Drewco piece on workholding, we quickly identified an interesting angle there, as well. Drewco is known throughout the gear man- Chad Morrison ufacturing industry as a company that takes a personal, hands-on approach VICE PRESIDENT to meeting its customer’s individual needs, so we thought that a couple of case studies outlining the challenges the company’s product designers have Teresa Hall successfully met would be fitting. The article’s author, Matt Peterson, has OPERATIONS/ done a great job of identifying and describing these projects, and we’re CIRCULATION indebted to him for his excellent work. In addition, we’re pleased to present yet another installment on the PRODUCTION issue of workplace safety by our resident expert, Terry McDonald. As an aside, Terry’s columns have resulted in a great number of comments from Andy Spain our readers, and all of them have been very supportive and appreciative of ART DIRECTOR his informed and realistic approach to encouraging safe work habits. And we’re also delighted to present Ray Lawler, president of the Lawler Gear Corporation, in our company profile, and to feature Greg Allen—world EDITORIAL traveler and founder of the Greg Allen Company—in our new Q&A department. Interesting people, all, and each with a fascinating story to tell. Russ Willcutt So we hope you’ll enjoy reading this issue of Gear Solutions as much as MANAGING EDITOR we have pulling it together. As always, we welcome your comments, sugges- tions, and submissions, which you can send to editor@gearsolutionson- CONTRIBUTING WRITERS: line.com or to my own address, which is listed below. We look forward to Michael Hayes hearing from you! Terry McDonald Matt Peterson

David C. Cooper Publisher The views expressed by those not Gear Solutions magazine on the staff of Gear Solutions [email protected] magazine, or who are not specifically (800) 366-2185 employed by Media Solutions, Inc., are purely their own. All “industry news” material has either been submitted by the subject company or pulled directly from their corporate Web site, which is assumed to be cleared for release. Comments and submissions are welcome, and can be submitted to 4 GEAR SOLUTIONS • JULY 2003 • gearsolutionsonline.com [email protected].

industryNEWS New Products, Trends and Developments in the Gear Industry

to field conditions. In addition, all shaft keys (input and output) are Tyrolit and Bosch Develop Tool-Free Disc Change now captured by drilled and tapped socket head cap screws, making Tyrolit and the German electronics group Bosch have achieved installation easier and avoiding the potential for losing loose parts. a technological breakthrough in angle grinding. In a three-year The 55 CDR model also features an enlarged drain plug arrange- collaboration, the two companies have developed the first SDS ment, allowing for faster, more-reliable drainage of the gearbox. quick-clamping system for angle grinders found worldwide. The “These improvements new technology has been increase the durability and patented, which leads to reliability of our conveyor Worcester Gear adds a an international competitive drives, making maintenance Quick Drill Stretch advantage. an easier, simpler task,” Continuing its commitment to meet The revolutionary SDS says Barry Hall, director of its customer’s delivery needs, hold system allows a tool-free operations at Philadelphia down costs, and expand its second- disc change for the first Gear’s Midwest Regional ary operation capabilities, Worcester time ever in angle grinders. Service Center. “In addition, Gear recently purchased and installed Hook wrenches or other the improvements should a Quick Drill Stretch, manufactured ancillary tools are no provide longer service life for by Quick Mill of Peterborough, longer necessary with Bosch SDS grinders. The disc is attached to these conveyor drives, ulti- Ontario. The Quick Drill Stretch is a computer-driven drilling station that the tool and affixed by a quick turn. Thus, accessories hardly ever mately saving our customers also taps and c-bores. Its table get lost. The new Tyrolit grinding wheels are also compatible with both time and money.” measures 36” x 180” and can conventional grinders (without SDS). Philadelphia Gear is accommodate a workpiece with a Tyrolit has been producing cutting and grinding wheels for angle known for its long-lasting height up to 18”. grinders since September 2002. The product line includes cutting and reliable selection of The Quick Drill Stretch improves wheels for steel plates, pipes, and reinforcement rods, as well as automotive conveyor gear Worcester Gear’s efficiency in per- rough grinding wheels for finishing weld seams or deburring steel. drives. Such drives can be forming these secondary operations Tyrolit also produces diamond grinding wheels for tiles and flagstones. found in wide use in auto- on racks and for other appropriate Tyrolit is one of the world’s leading manufacturers of bonded grinding, motive plants throughout drilling applications. This should cutting, sawing, and drilling tools, and it attaches great importance to the United States. help Worcester Gear to meet its innovation and precision. More than 100 researchers and applica- A founding member of customer’s time-critical delivery tion engineers at the headquarters in Schwaz/Tirol are constantly the American Gear situations and cost targets. developing and improving high-quality Tyrolit products. Manufacturers Association For more information, visit the For more information, access the Tyrolit Web site at [www.tyrolit.com] (AGMA), Philadelphia Gear Worcester Gear Web site at or visit Bosch at [www.bosch-pt.com]. offers products and servic- [www.wgear.com]. es found in use worldwide; Improved Automotive Conveyer Drives from conveyor gear drives used in long-wall coal mining operations, to emergency repair services critical to the power generation indus- from Philadelphia Gear tries. The company serves thousands of customers around the globe Philadelphia Gear Corporation, a full-service provider of gearing and from its regional service and manufacturing facilities in New Castle, power transmission solutions, announces product improvements to Delaware, Birmingham, Alabama, Chicago, Houston, and Los Angeles. its durable and reliable line of automotive conveyor line gear drives. Philadelphia Gear is headquartered in Norristown, Pennsylvania. Bulls-eye sight flow For more information, contact Thomas Chaump at (800) 766-5120, indicators have been or send e-mail to [email protected]. Visit the company’s added to both the 55 Web site at [www.philagear.com]. and 155 CDR conveyor units. These new indicators allow for the oil level to be determined at a glance, removing the possibility of the old-style standpipe breaking in operation. In addition, the new sight flow indicators New Arm Control/Laser Tracker Combo from FARO virtually eliminate the possibility of overfilling gearboxes in operation. FARO Technologies, Inc., has released two of its top-selling portable Shaft lip seals for these units have been upgraded from “Buna N” coordinate measuring machines (CMMs) in a single package. The material to “Viton,” providing longer service life and more tolerance FARO Combo Package unites the company’s Platinum FaroArm

6 GEAR SOLUTIONS • JULY 2003 • gearsolutionsonline.com Smooth, Silent Transcyko® cycloidal speed reducers are as smooth as they are silent. Cycloidal Speed Reducers Available from Transcyko Transcyko® cycloidal speed reducers are smooth, silent, operate without vibration, and can absorb extremely high shock loads in excess of 500 percent. The reducers also come with a two-year warranty. Transcyko cycloidal speed reducers are available in a wide range and combination of sizes, ratios, input power, mountings, and configurations. Reduction ratios are 6:1 through 119:1 per stage, through 7569:1 double and 658,503:1 triple reduction. Input horsepower is from 1/16 to over 200HP. Output torque is in excess of 500,000 in. lbs. Transcyko cycloidal speed reducers are fully compatible with current cycloidal speed reducers on the market. For more information, please call Lindsay Lawrence or Don Paulsen at (604) 736-7301, or send e-mail to [email protected]. The company’s Web site can be accessed at [www.hyatt-transcyko.com].

The World of Hard Gear Finishing

Gear Honing Hard Broaching Dressing Devices

Fässler Corporation, 131 W. Layton Ave., Ste 308, Milwaukee, WI 53207-5941 U.S.A. Phone +1 (414) 769-0072, Fax +1 (414) 769-8610, [email protected] www.faessler-ag.ch

gearsolutionsonline.com • JULY 2003 • GEAR SOLUTIONS 7 Control Station®—the original and only long- one in order to provide manufacturers the reach (four to 12 feet), “six degree of free- feedback they need to make their products dom” probe on the market—with the FARO the very best they can be.” Laser Tracker Si®, which has a range of 230 Also significant is the fact that the FARO feet. Both systems share the same CAM2 Combo sells for $20,000 less than the Measure® software (on the same PC or sepa- latest innovation in laser measurement, cost of purchasing the technology sepa- rately), so all of the data is easily accessible. the FARO Tracker,” says Simon Raab, pres- rately, regardless of the FaroArm’s size. “The FARO Combo pairs the portable ident and CEO of the company. “So it’s The Platinum FaroArm offers .0005” metrology standard, the FaroArm, with the really two CMMs working seamlessly as accuracy and enables users to inspect, reverse-engineer, or perform CAD-to-part analysis. Its adaptable 3-D measurement technology and customized zero-training Soft-Tools (with or without CAD) make it ideal for forming, molding, fabricating, casting, and assembly facilities needing GD&T and SPC output. Despite being durable enough for harsh manufacturing environments, it is considerably lighter than standard portable CMMs, and includes on-board, extended-use batteries. The FARO Laser Tracker uses an ultra-precise laser beam to allow operators to measure and inspect objects up to 230 feet, while on-site and in-process. It offers porta- bility in measurement with high accuracy W.M. Berg Introduces Metric/Inch Shaft Adapters New shaft adapters developed by W.M. Berg are an excellent method to inexpensively convert metric shaft to a standard inch-sized shaft. They are high precision, with tight tolerances on bores, shank, and bore/shank concentricity, and they come in both pin hub and clamp style hubs. The comprehensive varieties include inch and metric males to inch and metric females, and in both hub styles. As a complementary product to its precision couplings and precision and ultra-precision shafting, they provide a complete solution to many power transmission problems. These components solve a common problem: trying to couple shafts of two different sizing conventions. It is very uncommon to find as a standard

8 GEAR SOLUTIONS • JULY 2003 • gearsolutionsonline.com (.001”), and faster measuring speeds and FARO’s portable CMMs enable manufactur- than 10 new patents pending for innovations larger working envelopes than any other ing, engineering, and quality control profes- in accuracy, reliability, and ease of use. optical method. With its greater sionals to measure and inspect parts, FARO Technologies, Inc., and its interna- angular resolution, repeatability, and accura- machine tools, and other objects on-site, tional subsidiaries design, develop, and cy, it advances proven tracker technology in-process, or wherever it’s most efficient market software and portable, computer- with SuperADM (Super Absolute Distance and cost-effective. The company’s three new ized measurement devices. The company’s Measurement). This high-speed distance products—the FARO Gage, Platinum FaroArm, products allow manufacturers to perform measuring capability allows the user to and the FARO Laser Tracker—represent the three-dimensional inspections of parts and measure effectively even if the laser beam culmination of two decades of R&D with more assemblies on the shop floor. This helps has been interrupted. “Combining these two technologies creates an immediate ROI,” says FARO Hardware Product Manager Shaun When Precision Holding is Critical, Mymudes. “A manufacturer can use the FARO Laser Tracker Si for all of their large- volume, 3-D scanning applications. Once the Answer is Hydra-Lock. those reference points are established, they can then use the Platinum FaroArm’s Originators & Developers of Hydraulic Holding six degrees of freedom to reach the hidden points that all other tracker systems miss. Hydra-Lock arbors and chucks are Hydra-Lock Corporation originated That means that for the first time ever, they have the ability to measure anything, designed to facilitate all types of and developed the concept of any size, anywhere, and simultaneously, precision gear processing. We have the of hydraulically expanding arbors with no line-of-sight limitations—and all on ability to hold and precision locate on and chucks. 50 years of continuous the same software interface.” the pitch diameter of all types of research and development has resulted in Hydra-Lock’s unmatched product couplings that have one bore spline and gear forms. Improve expertise in the production of that is inch, and the other that is met- quality and cut costs by using super- sophisticated precision workholding ric. Using this new product, the need accurate Hydra-Lock arbors and chucks to hold parts and devices. Our engineers welcome for the repeated purchase of special tools used in hobbing, shaping, “specials”, particularly the most couplings can be eliminated. shaving, grinding and inspection demanding, which provide a motivating Many machines run metric gearing operations. challenge for us! with metric bores, and many times in design, it is necessary to run metric gears on inch-machined shafts, or inch gears with metric shafts. These new shaft adapters eliminate the need for custom shafting by convert- ing the shaft from a metric size to an inch size, or from an inch size to a ISO 9001 Certified metric size. Because of the product’s Hydra-Lock’s full-line of products include high precision, gears can be mounted arbors/chucks for grinding, turning/gaging, directly onto shaft adapters, eliminat- balancing, drilling, reaming, honing, milling ing the need to have a custom jour- & boring. Newly developed arbors/chucls for maximum expansions & contractions with nal on the shaft or having to custom movements up to .250” or greater. bore the gear. Custom lengths, bores, hubs, and outside diameters Hydra-Lock arbors and chucks can be 800-634-6973 made with expanding or contracting diame- are available upon request. ters to any of the above shapes or variations of these. For more information, access the W.M. Berg Web site at [www.wmberg.com]. www.hydralock.com email: [email protected]

gearsolutionsonline.com • JULY 2003 • GEAR SOLUTIONS 9 eliminate manufacturing errors, thereby operating in high-torque, high-angularity increasing productivity and profitability for a applications. variety of industries in FARO’s worldwide Formula 800 is an extreme pressure customer base. Principal products include (EP), high viscosity lubrication compound the FARO Gage, Platinum and Titanium that effectively reduces coupling wear and FaroArms, the Control Station measure- maintenance costs by getting between the ment system, the FARO Laser Tracker, and teeth of gear couplings and staying put. a CAM2 family of advanced CAD-based General purpose greases, including most measurement and reporting software. with an EP additive, can’t hold up to the FARO Technologies is ISO 9001-certified severe sliding forces and accompanying and Guide 25 approved. frictional heat generated by couplings as For more information, visit the company’s they transmit vast amounts of power to Web site at [www.faro.com]. huge mill stands. These ordinary lubricants quickly break down, resulting in premature Xtek Develops Formula 800 wear to the gear components. Formula 800 Coupling Compound is Coupling Compound different. Blended from the finest Formula 800 is the result of more than hydrotreated paraffin base stocks and two years of extensive research and PAO synthetic oils, it contains a propri- development by a consortium of scien- etary blend of EP additives, graphite, and tists and engineers, and it has been field molybdenum disulfide. This package of tested in tough, hardworking rolling mills ingredients provides a dramatic one-two across the United States. Formula 800 is punch. First, the EP elements give superior a lubricant that provides unprecedented resistance to the high temperatures resistance to the exceptional heat and caused by sliding action. Then the friction generated by gear couplings Comparative graphs demonstrating Xtek’s Formula 800 Coupling Compound. graphite and molybdenum components (from Xtek white paper)

10 GEAR SOLUTIONS • JULY 2003 • gearsolutionsonline.com work to synergistically prevent surface damage under even the customers with unsurpassed leadership in the specialty crane and most extreme operating conditions. remote-handling fields. This combination of base stocks and special additives allows PaR Systems designs and manufacturers remotely and robotically Formula 800 to operate over wide temperature ranges with excellent operated specialized cranes with telescoping masts and manipulator thermal stability and extreme resistance to oxidation and washout. arms for handling of hazardous materials in the nuclear utility What’s more, the superior field application results have been sup- and Department of Energy markets, and gantry robots with wide ported by high scores in independent laboratory tests. Formula 800 area coverage for process applications in the aerospace and exhibits a very high viscosity index and the highest load ratings in marine industries. Ederer also serves a broad base of customers, both the four-ball load and Timken OK load tests. providing custom-engineered bridge, gantry, and revolver cranes, For more information call (888) 332-9835, or visit the company’s and specialty crane-related material handling equipment, for nuclear Web site at [www.xtek.com]. utilities, Department of Energy facilities, aerospace, forest products, primary metals, ports, marine, and other heavy industrial applications. Ederer Acquired by PaR Systems, Inc. For more information, contact Carrie Koliha at (651) 484-7261, or PaR Systems, Inc., has announced the acquisition of the assets visit the company’s Web sites at [www.par.com] or [www.ederer.com]. and operations of Ederer Incorporated, which is located in Seattle, Washington. Ederer, LLC, will operate as a wholly owned subsidiary of PaR Systems. To ensure the continuation of Ederer’s strong Online Technical Drawings knowledge base and industry leading reputation, all active Ederer Available from Philadelphia Gear employees will remain with the business. Ederer will continue to Philadelphia Gear Corporation, a full-service provider of gearing and serve customers from its Seattle location. power transmission solutions, announces the online availability of PaR will relocate a senior leader to lead the integration of PaR’s technical drawings for operational excellence model and corporate values within the Philadelphia Gear Ederer organization. Integrating Ederer’s 100 years of specialty customers, through crane design and manufacturing experience with PaR’s 42 years of www.philagear.com. remote handling and robotics experience will provide PaR/Ederer Philadelphia Gear customers can request technical gearbox drawings at no cost via the “Drawing Request Form” page online (found

gearsolutionsonline.com • JULY 2003 • GEAR SOLUTIONS 11 in the “Manuals & Literature” section). Available drawings include outline dimension drawings, layout drawings, and, in the case of high Twelfth Annual AGMA speed drives, mass-elastic drawings as well. All drawing requests Gear Failure Analysis Seminar are processed within 48 hours. You can avoid gear failure and save thousands of dollars in repair To effectively execute a drawing request, customers need only costs. It’s all about knowing what causes gear failure and how to provide a “unit serial number” and an “order number,” located on prevent it from occurring. Attend AGMA’s technical education seminar the nameplate of each Philadelphia Gear enclosed drive. Customers on gear failure analysis and come away with a can also include the unit’s “size and/or type” for a potentially faster complete knowledge of gear failure—what to fulfillment of their drawing request, but this information is optional watch out for, and how to fix it. and will not prevent Philadelphia Gear from honoring customers’ The seminar will be held July 17-18 and requests. Customers should also specify the type of drawing they September 29-30, 2003, at the Big Sky Resort desire within the “Comments” section, include outline dimension, in Big Sky, Montana. Please note that there is layout, and/or mass elastic. limited seating and that this seminar fills up In over 100 years of operation, Philadelphia Gear has amassed an quickly every year. extensive collection of technical drawings utilized by engineers and In this seminar, you’ll examine the various types of gear failure, regional centers for service and repair. Available technical drawings such as macropitting, micropitting, scuffing, tooth wear, and break- contain such information as dimensions for input and output shafts age. Possible causes of these failures will be presented along with and other technical information enabling engineers to ensure proper some suggested ways to avoid them. alignment and to resolve unit footprint issues on-site. Gear failure analysis expert Robert Errichello will use a variety of “Our online presence allows Philadelphia Gear to offer our tools—lectures, slide presentations, hands-on workshops with customers more of the resources we’ve accumulated in over 100 failed gears, and question and answer sessions—to give you a years of providing gearing solutions,” says Carl Rapp, President comprehensive understanding of the reasons for gear failure. and CEO of Philadelphia Gear. “The technical drawings now avail- Handouts include Errichello’s Failure Analysis Textbook and Gear able are another of the helpful resources customers can utilize Failure Analysis Atlas. via our Web site.” To be placed on the waiting list, contact AGMA’s Technical For more information on Philadelphia Gear, call (800) 766-5120, Division by e-mail at [email protected] or phone AGMA headquarters or visit them online at [www.philagear.com]. Queries can also be at (703) 684-0211. If you’re reaching us via e-mail, please made to Thomas J. Chaump of FCF Schmidt Public Relations at provide the dates you are interested in, your affiliation, and (610) 941-0395 or [email protected]. contact information.

12 GEAR SOLUTIONS • JULY 2003 • gearsolutionsonline.com terryMcDONALD Member of the ANSI Subcommittee on Gear Safety

a horizontal hobbing machine doing his job. SAFETY MATTERS The tank was located at the rear of the machine, and while he was performing his Common-sense commentary on how easy—and important—it is job, the operator continued to run parts to stay sharp on the job when it comes to safety. on the machine. This was a dangerous would like to expand on my comment in While we’re discussing guarding I would enough practice in itself, but to compound the last column concerning cleanliness of like to point out that in the ANSI B11.11 the problem the guard—which was intended I the work area. You may not think of this as standard, which is available through the to cover the drive belts, and was also a safety issue, but I find that a clean, organ- AMT, guarding requirements for various located in the rear of the machine—had ized work area is one of the best deterrents to types of gear cutting equipment are well been left off. No one there seemed to those nagging little injuries that seem to occur defined. There is another area of this sub- know why the guard was off. Fortunately, no matter what. I find that if I allow my employ- ject to bring up, as well. I see many cases no one was hurt that time, but you can ees time to clean up and organize tools and where the existing guards on machines in imagine the consequences if something tooling, clean the machine, and keep their work shops are not being used or have been had happened. This was just an accident area neat and free of oily floors and surfaces, bypassed. When I question this, I am often waiting to happen. Whether you’re an not only do they per- told that they were operator, maintenance man, supervisor, form better, but there It doesn’t take any extra taken off for main- or manager, please be observant. Apply is virtually no lost pro- time or effort to be tenance or cleaning what guarding is available, and you may duction. I consider willing to question unsafe and that it was just just save a fellow employee from a bad this time a necessary conditions in the easier to leave injury—or even worse. requirement for oper- workplace. them off. Another Much too often, we all ignore unsafe ating a safe shop. reason I’m given is practices that are in our power to correct. Many of us have older equipment cutting that they (the guards) were in the way and We can all make a conscientious effort to gears in our shops. When we look longingly slowed down production. While these prac- recognize and resolve these issues before at the newest CNC gear-cutting equipment tices may seem to save time, in reality they anything unfortunate occurs. It really doesn’t at shows or in advertisements, we note that could halt productive time completely should take any extra time or effort; it just requires these machines seem to have much better an injury occur. It is a major requirement of keeping an eye open and being willing to guarding systems than those on our older, our positions as supervisors or managers question unsafe conditions. No one wants “vintage” equipment. While it is not practical that we halt these practices immediately. to get hurt on the job, and most people to attempt to duplicate this guarding on our I was recently in a medium-size gear are more than willing to help make condi- older machines, it is possible to upgrade. cutting shop and observed the gentleman tions safer, both for themselves and their Many of the manufacturers—or those who who had the job of refilling the coolant on fellow employees. are still in business, at least—can provide upgraded guarding for these older machines. ABOUT THE AUTHOR: And even if we can’t obtain these updates With more than 30 years of experience in the gear industry, Terry McDonald is a manager from the original manufacturers, there are with Repair Parts, Inc., a partner with Re-New Machine & Maintenance, Inc., and a current many generic guards available through the member and past-chairman of the American National Standards Institute B11.11 various tool supply houses that can be Subcommittee on Safety Requirements for Construction, Care, and Use of Gear Cutting applied with little or no modifications. These Equipment. McDonald writes this monthly column specifically for Gear Solutions magazine. guards are not very expensive and could He can be contacted through the magazine at [email protected]. Responses and keep a serious injury from occurring. reactions to his column are also welcome.

gearsolutionsonline.com • JULY 2003 • GEAR SOLUTIONS 13 Company Profile__

From a four-man operation to a thriving business employing some two-dozen experienced workers, Lawler Gear provides an interesting mixof gear-related services.

LAWLER GEAR Corporation

14 GEAR SOLUTIONS • JULY 2003 • gearsolutionsonline.com It was 1952 when a small-town blacksmith by the name of Since that time, the company has grown steadily, but Lawler Calvin Lawler was drafted into the Korean War effort. He says he can look back and identify certain turning points that had just completed basic training when he signed up for a helped make the business a success. The first came in 1981, three-month course at an Army base in Atlanta that would when the company invested in its first CNC lathe. “That prepare him to man a mobile machine shop mounted in might not sound like a big deal now, but we were really on Ithe back of a two-ton truck to do repair work as necessary the cutting edge for a shop our size back then.” near and along the front lines. He was just glad that he’d Along with the acquisition came certain challenges, have a truck instead of a foxhole to sleep in, according to though. “In those days, you couldn’t hire a CNC machinist his son, Ray Lawler. to save your life,” he says. “Of course, it’s the exact opposite “The way it turned out, though, is that dad was so good at now. These days it’s hard to find a manual machinist.” it that they kept him on base to teach the course,” Lawler Another turning point came the next year, when Lawler says, “so he never even had to leave Atlanta during the two purchased the company’s first computer. “It was a years he was in the military.” RadioShack Model 3, and it had something like 48K of Returning home to Missouri, he found that the local farmers memory, which is laughable now, since saving a Word docu- had figured out how to do without his blacksmith services ment alone takes about 20K,” he says. “But I’d learned how during his absence, so he relocated to Kansas City, where he to write computer code in college, so I’d bought it to help us spent 15 years work- do our gear cutting calcu- ing in machine shops, lations, which were taking and then another us forever to do by hand.” decade with a company Writing and debugging a that made tooling for gear quoting program stamping operations. took Lawler more than six As a result, Ray weeks, and when it was Lawler’s father was 50 printed out line by line, it years old before he measured 14 feet long. decided to start a “But it was well worth the business of his own. effort,” he says. “To manu- “He started off with ally quote a gear would two full-time employ- take us about 45 minutes ees in a little 3,000 to an hour, and you just square-foot shop, and hated doing it. Plus you the reason he got into were making so many The Lawler family (from left): Shop Foreman Wayne Lawler, Vice-President Ray Lawler, gears is because Treasurer Pauline Lawler, and President Cal Lawler. decisions right out of your everybody was doing head that you could do a basic machining, so he thought he needed to do something quote one day and the same quote three weeks later and it different to set the company apart,” says Lawler. “I decided would be completely different,” he says. “Once I’d gotten the to join him about six months after that.” program written, the quotes came out the same every time, Lawler had started running a mill and lathe in his dad’s and the time it took to do a quote dropped from an hour to home shop even before he was a teenager, and he then two minutes, which let us do a lot more quotes. And the attended a vocational technology school while in high more you do, the more work you get, which is exactly what school where he studied drafting and architectural drawing happened.” before going to work for the Allis-Chalmers Corporation. With the additional work, the company needed more “They had a combine plant in Independence, Missouri, and room, which led to yet another major turning point. “We’d I was in their product engineering department, working on started out in 1978 with 3,000 square feet, and then we my engineering degree at night,” he says. “I had to put off moved to a 7,500 square-foot building a year later, where we school when I went to work with dad, but then I switched stayed for the next 10 years,” says Lawler. “But we built our over to manufacturing and eventually graduated. Thing is, own 20,000 square-foot building in 1989, and then added because of the hands-on experience I was getting, I already another 11,000 square feet in 1996, and that has made all knew almost everything I needed to know about manufac- the difference.” turing once I’d earned my degree. But I wanted to finish Finally housed in a facility built specifically for the work what I’d started.” they were doing, and with an overhead crane that allowed In the early years, the Lawler Gear Corporation focused on material to be moved more quickly and efficiently, the com- doing gear and tooling work, but it wasn’t long before they pany was poised for growth. “Our profitability went up just decided to get away from tooling to concentrate on gears. because of the improved efficiency,” Lawler says. “It was really “When you’re working with gears, you’ll always have some amazing.” turning to do, like grinding on shafts and secondary mill- Although Lawler Gear’s focus remains on gear manufactur- work. So we found that if we just stuck with the gears, it ing, it offers additional services as well, such as gear inspec- seemed to automatically fill up the rest of the shop with tion. “We put in an analytical testing lab several years ago, work,” Lawler says. and it’s really come in handy,” says Lawler. “We mostly use

gearsolutionsonline.com • JULY 2003 • GEAR SOLUTIONS 15 the gear lab for internal purposes, This gear hobber with 90” capacity is one of the many machines in Lawler’s arsenal. making sure we’re doing a good job on the gears and deciding which machines need to be repaired, but we offer the service to our customers as well.” The testing service has even proved handy for pulling in new business, he says. Lawler recalls a potential customer who was having trouble with gear noise and brought in some of his gears to be checked. “The inspection machine prints out a little strip chart, and the first gear we put in was so bad that the lines went right off the paper,” he says with a laugh. “So we found out that the guy who was supplying this gear didn’t know what he was doing, and we were asked to make a sample, which the new customer loved. We picked up a contract worth about $50,000 a year.” Another service the company provides involves reverse engineering.

16 GEAR SOLUTIONS • JULY 2003 • gearsolutionsonline.com Lawler says that customers will bring him a gear from a nothing more than a calculator, which took forever. It manufacturer that’s gone out of business, or the OEM is still could take three to five hours to find four gears that would in business, but the delivery time may run 10 or more weeks, equal a decimal for a helical gear train. Then we got our and the customer can’t afford to wait. “Fact is, if you can hands on a book that had 16,000 gear trains already wait 10 weeks for the part, then you don’t really need the worked out, and we thought we’d died and gone to heav- machine,” Lawler says. en. And then we purchased a set of books that had some- The work is rewarding in other ways, as well. Many gear thing like 650,000 gear trains, which was just unbelievable. manufacturing companies would rather work from plans Then computers came along and we wrote a program to than samples, but by rejecting reverse engineering projects find the four gears, and the time dropped down to about they miss an opportunity to form lasting relationships with 20 minutes on an old 486 computer. These days it takes their customers. “I really like taking the jobs that nobody about two minutes to run the same program, but you still else wants to do,” says Lawler. “We end up making some find yourself drumming your fingers on the table and really bizarre looking parts sometimes, and yeah, it takes a getting restless.” lot of thought and a lot of tooling and a lot of trial and With this technology now available to everyone, though, error to get it worked out and running smoothly, but you it’s that much harder to separate yourself from the pack, typically get a premium for the part, and you don’t have Lawler says. But he and his family—which includes Calvin, everybody in the country trying to take that business away who is now 75 and semi-retired, his brother Wayne, who is from you. Once you get a job like that, and you take care of the shop foreman, and his mother, Pauline, who handles the the customer, that business is yours forever. Plus you need to bookkeeping—still keep their eyes focused on whatever’s get one of those jobs every once in awhile just to clear all coming down the road. He says that’s one of the things that the cobwebs out.” keeps the company sharp. “Everybody else is moving for- Lawler says he’s amazed when he thinks of all the ward, and if you’re standing still, they’re going to leave you advances that have been made in the industry in the past behind,” Lawler says. “If you’re not moving ahead, then 25 years. One example, he says, involves calculating gear you’re really moving backward.” trains. “That’s all gearing is, tons of formulas,” he says. “In For more information on the Lawler Gear Corporation, call the early days, we had to figure everything by hand, with (816) 525-0002, or send e-mail to [email protected].

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gearsolutionsonline.com • JULY 2003 • GEAR SOLUTIONS 17 Custom Solutions for Workholding Challenges At a time when everyone has access to the same manufacturing technologies, the Drewco Corporation is helping its customers stand out with tailored solutions to their workholding needs. By Matt Peterson

18 GEAR SOLUTIONS • JULY 2003 • gearsolutionsonline.com SPEED, EFFICIENCY, COMPETITION, ACCURACY… ALL WORDS THAT FUEL THE FIRES OF MODERN-DAY MANUFACTURING. THEY ARE THE “WHY” BEHIND OUR DAILY TASKS, AS WELL AS THE REASONS FOR INVENTION AND THE MOTIVATION TO COMPETE—AND WHAT DRIVES US TO COMPETE ALSO FORCES US TO IMPROVE. TODAY’S GEAR MANUFACTURING ARENA IS FILLED WITH OBSTACLES THAT CHALLENGE US TO FIND SOLUTIONS TO PROBLEMS BOTH OLD AND NEW. AND WHILE MANY OF THE PROBLEMS FACING MANUFACTURERS 100 YEARS AGO HAVE NOW BEEN RESOLVED, TODAY WE’RE MAKING IMPROVEMENTS ONE MICRON AT A TIME. >>>

gearsolutionsonline.com • JULY 2003 • GEAR SOLUTIONS 19 all know that manufacturing gears can be a Wevery fussy process, and the various classes that have been developed to define tooth form accuracy are evidence of the fact that the target is getting even smaller. Gear manufacturers are constantly being challenged to improve their operations, and often with no increase in cost. That’s why engineers must continue to improve the efficiency of the actual manufacturing process. At the Drewco Corporation, our interest in solving work- and tool-holding problems goes far beyond issues of accuracy. In addition to holding tight tolerances, our challenge is to maintain accuracy while building universal tooling that will help customers compete in today’s just-in-time marketplace. Nobody can sustain vast inventories any longer, so the solution is to either get suppliers to hold inventory, or to devise faster set-ups. While the cost of set-ups would be absorbed by mass production numbers, with just-in-time quantities on hand, the time spent setting up represents a large part of the total cost and can’t be absorbed so easily. The result is that today’s manufacturers must find quicker set-ups. In response, we have focused on helping our customers develop quick-change procedures, and a couple of examples 12024 E. Nine Mile Rd. • Warren, MI 48089 highlight the unique concepts we’ve developed. One project e-mail: [email protected] allowed us to develop fixtures that share tooling between three existing machines of different makes—machines that must be able to run any of the 32 gears that need short-run Please Fax Us Your RFQ’s! production on a month-by-month basis. A second example involves the use of the internationally designed HSK (586) 754-8923 • Fax (586) 754-8926 adapter, which provides incredible repeatability as well as quick tool changes.

LAWLER GEAR CORP. Three-Part Challenge LEE’S SUMMIT, MISSOURI The challenge presented to Drewco by one customer involved developing specialized tooling that would accommodate specific short-run work, could run on a variety of existing machines, and could be changed over with ease. For the engineers, the challenge involved tooling up three hobbing machines, with different mounts and limits, so they could utilize the same tooling between them. With three Gear Manufacturing machines, and over 30 set-ups, the engineering team set out (from singles to production to shave off as much time as possible. Three main issues & reverse-engineering services) needed to be addressed in order to accomplish this task:

SPUR — HELICAL — SPLINE — WORM — BEVEL — RACK • The various part sizes of the gears, both ID and OD Gear Hobbing • Gear Shaping • Gear Rack • Sprockets • The ability to change over quickly Broaching • CNC Turning • CNC Milling • Automatic Sawing • Mounting the tooling to three different machines

Part sizes—In order to hold each of the various part sizes securely enough to allow ample metal removal for competitive production, a double clamping set-up was employed. This combination used face clamping as well as ID or OD A HANDFUL OR A TRUCKLOAD! chucking. The chucking on the ID/OD centralized the part and guaranteed the concentricity requirement necessary in the design of the gear. The face clamping aspect offered the LAWLER GEAR CORP. rigidity that was required for the rapid metal removal. 1320 S.E. Hamblen Road • Lee’s Summit, MO 64081 The two clamping methods ensured the quality required as Toll Free: 800-346-3038 Missouri: 816-525-0002 • Fax: 816-525-1113 long as they were timed properly. The diameter chucking needed to happen first, which would locate the part according

20 GEAR SOLUTIONS • JULY 2003 • gearsolutionsonline.com Quick change fixture for 32 1gears

Adapter base for 32 gear quick change

There are many things to consider when placing an order with a gear manufacturer, such as trust, confidence and level 2 of integrity. Money is also a primary concern in these down economic times, but so is getting a reliable product, on-time that fits YOUR particular gear needs. Three bolt quick change over Being late due to lost time on the production line or receiving a poor quality product will NEVER happen with Carnes-Miller Gear, guaranteed! For over 30 years, we have maintained a strict quality control process from reviewing specs,to delivering 3 a final flawless product... all at a competitive price with no surprises, no hidden costs.

HSK quick change collet We make it easy for our customers to buy from us. We want fixtures each of our new or existing customers to have a positive, risk-free experience, with every single order they place. No job is taken for granted. We appreciate your business and in return take care of your budget and project concerns by 4 offering an affordable, worry-free package solution. Give us the chance to earn your business by letting us quote HSK quick change base on your next order. We will work together to get a "do-able" and adapter solution and cost package that works for YOU. At Carnes-Miller Gear, we assure you that we will handle your account and your projects,with professionalism and accuracy.

Let us be a part of your solution.Call us to discuss your gear needs. 5 Call us at: 1-800-273-6814

to a specified datum. On some parts this was an inside diame- Carnes-Miller Gear...The Gear People® ter, while others were outside. The face clamps, which offered www.cmgear.com the rigidity, activated next. Used together, the two clamping methods were able to produce a repeatable, solid, predictable set-up to cut teeth. Drawbar-activated collets were designed for each datum 362 Browns Hill Road • P.O. Box 268 • Locust, NC 28097 locating surface. This amounted to 32 different collets, but

gearsolutionsonline.com • JULY 2003 • GEAR SOLUTIONS 21 to the minor diameter as possible, with a mini- mal amount of mass. The parallelism accuracy of this detail translates into gear teeth that sur- pass perpendicularity requirements. These details needed to be changed for each different gear along with the collet. The subassemblies, too, had to be changed from time to time.

Quick change—Have you ever tried to put a square pin in a round hole? That’s what it feels like when you try to put a round shaft into a round hole with only two to five microns of clearance between them. And that’s the kind of allowable tolerance, used in mounting the subassemblies, that will give the accuracy required when cutting gears. How can the assembly and disassembly of these characteris- tically stubborn fits be accomplished quickly? only three designs. This allowed for a reduced number of The solution revolves around the hexagon. sub assemblies: one assembly for the OD gripping collets, By removing six sections of the circle on both the male and two for the ID. This aspect of the project reduces and female part of the assembly, we were able to produce changeover time by limiting the amount of tooling, also the desired fit with the desired assembly/disassembly speed. reducing the initial investment in the same manner. A slight twist between the two parts moves the contact The face clamp sets also numbered 32. This aspect of the points of the tight tolerance diameters into a bind-free zone design had to be unique for each gear. They resemble a mix- that allows for immediate separation. The face contact ing bowl with holes, and their size and shape would push the between the two pieces prevents any of the misalignment clearance envelope. The intent was to get support out as close that would cause the binding problem.

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22 GEAR SOLUTIONS • JULY 2003 • gearsolutionsonline.com This part of the design is complimented by the addition of Three machines—In this case, the challenge was to fit this a slotted bolt circle. By including the radial slot, assembly tooling with the three machines the customer owned. It involves simply loosening the mounting bolts and twisting originally involved two NC machines before the third to a point where the bolt head will slip through the mating machine was added in mid-design—this was the old standby part. This three-hole bolt pattern was also used to mount the machine that will never die. Each machine had its own face clamps, and this action allows the two-piece fit to occur design for mounting our package to and its own actuating without completely removing the bolt. If you tried separat- mechanism, and each had its own work envelope. Satisfying ing the two parts, first with and then without the hexagonal all three machines was a clever accomplishment in itself. design, you would surely agree that this design saves a Each machine was given its own main base that would tremendous amount of time—not only by freeing up the accept the families of tooling and allow them to run any of tight tolerance between the two parts, but also because of the gears required. These three mounting details enabled the the time saved in threading the mounting bolts. customer to store only one type of tooling for this depart- This design does have its drawbacks, however. It’s a chal- ment, thereby reducing the space required for the storage of lenge to build, and it requires more time to build. The tim- tooling and allowing for uniform shelving to keep the tooling relationship between the mounting bolts and the hexa- ing in a neat and orderly manner. gon is crucial and can be confusing. The direction and Two of the three machines had automatic drawbar mecha- length of the bolt slot must mirror the scallops and tapped nisms to hook up to, while the older machine needed to be holes of the mating part. The tight tolerance diameters, as manipulated manually. The net result was that we needed to well as perpendicularity, must be maintained. adapt to two different drawbars while giving clearance for a The net result of this design is providing the ability to wrench in the manually operated design. change from set-up to set-up in a few rather than several Over a six-month period we delivered families of details minutes. Break the three bolts loose, twist, remove the first that enabled our customer to produce the gears required, one set-up, insert the next set-up, twist, tighten the bolts, and month at a time, until the whole library of parts were covered. you’re ready to go. The size-on-size relationship ensures repeatability, while the hex allows for the quick mating process. As a result, both the engineer and those responsible Adapting the Answer for assembly are happy. A second example of quick-change tooling that Drewco

gearsolutionsonline.com • JULY 2003 • GEAR SOLUTIONS 23 offers utilizes the internationally designed HSK-style mount- machine spindle. This first set-up allows future changeovers ing system. Producing this aspect properly is another tricky to be well under a minute. endeavor. For those who are unfamiliar with this design, it The tooling required for this machine to run 13 parts can consists of a unique locking mechanism that is operated be stored on one shelf and represents a small portion of the with a single hex key. What’s amazing about this design is total turnkey package. Considering the fact that set-up time the incredible accuracy that is repeated with such a simple has been reduced significantly, this package of tooling pays clamping devise. By tightening one screw, the inner compo- for itself quickly. nents pull the male and female parts together, creating a The Drewco Corporation has been involved in designing simultaneous contact between the locking taper and the creative tooling/workholding solutions for the past 66 years. faces. Thanks to this design, we are able to design tooling In providing solutions to the gear making industry, Drewco that can be switched out quickly and doesn’t require indicat- focuses on delivery, competitive pricing, and tight tolerance ing that the first set-up has been completed. quality, working with gear customers to constantly improve We were recently challenged to design quick-change tool- their production times, increase their profitability, and make ing for a series of smaller gears, which is a perfect applica- them more competitive in today’s market. tion for the HSK design. This time, there were 13 parts that needed to be run across just one machine, and the gripping To learn more, access the company’s Web site requirements for this family of parts were satisfied with collets alone. ID and OD chucking was again required, but the at [www.gmico.com], or call (262) 886-5050. activation of both collet designs came from a tailstock center. The HSK adapter made this design possible. ABOUT THE AUTHOR: The secret to our success in this case was the mating of the HSK system to our tooling. Keeping in mind that the HSK Matt Peterson is a production and quality control coordinator adaptor can only be assembled one way, we designed a and process engineer at the Drewco Corporation. He is cur- buffer piece between our tooling and the female socket of rently working toward his mechanical engineering technology the HSK system. This buffer employs a mounting method degree at the Milwaukee School of Engineering. He has with stirr-around screws. The first set-up requires an indicat- worked in production for 20 years, the past seven of them ing session that will marry the total assembly to the with Drewco.

24 GEAR SOLUTIONS • JULY 2003 • gearsolutionsonline.com

26 GEAR SOLUTIONS • JULY 2003 • gearsolutionsonline.com REINVENTING THE WHEELS

at Gleason Cutting Tools Corporation

Gleason Cutting Tools’ new superabrasives wheel plating facility is helping gear manufacturers keep pace with increased demand for high-performance hardened and ground gears.

By Michael Hayes

Gear designers around the world are seeking to increase their use of hardened gears to squeeze optimum per- Gformance out of smaller, quieter transmissions and gearboxes. After all, highly accurate hardened gears offer greatly improved strength and wear resistance (service life), while at the same time delivering a greater load carrying capacity (higher torque) than larger gears. But if the use of hardened gears solves many problems, it can also create a few. For example: where to find the super-accurate cubic boron nitride (CBN) plated wheels highly prized for the precision finish grinding of hardened gears after heat treat? Sourcing these wheels has always been notoriously difficult. Lead times are often long, quality usually suspect, and costs painfully high—until now.

gearsolutionsonline.com • JULY 2003 • GEAR SOLUTIONS 27 Controlling the Process Today, a new multimillion-dollar facility in the heart of the Midwest is doing what few thought would be possible just a few years ago: turning out hundreds of high precision, uniform, single layer CBN and diamond plated products a month for use in the hard finishing and grinding of bevel and cylindrical gears, as well as other non-gear profiles. Jay Werner, plated products manager at Gleason Cutting Tools Corporation, claims that the wheels made in this Loves Park, Illinois, facility are simply the best in the industry, and he has the facts to prove it. “Holding profile tolerances of 0.0001” to 0.0002” (one to two ten- thousandths of an inch) is routine for our wheels, and we have produced profile tolerances of 0.00005” (50 mil- Advanced Plating for CBN Wheels lionths of an inch) for some aircraft Gleason’s new plating facility is one of the most advanced of its kind in the world, with an expandable, ultra-modern gear applications,” says Werner. “I think electrolytic and electroless nickel plating capability currently producing up to 500 wheels a month. Products include non-dressable grinding and dressing wheels manufactured with hardened steel bodies, precision ground profiles, and many in the electroplating industry with nickel-plated single layer CBN or diamond crystals. Sizes range from 30 to 500 mm outside diameter, up to 160 would be shocked to learn that this is mm wide, and can accommodate any customer mounting requirement. Profile tolerances are at a level to meet even even possible. However, in the gear- the most stringent requirements of aircraft, automotive, tool and die, and carbide industries.

28 GEAR SOLUTIONS • JULY 2003 • gearsolutionsonline.com making industries, these accuracies are that are mechanically bonded to the imperative because of the critical nature “We’ve body with a layer of electrolytic and of gear profiles and surface finishes. proven that electroless applied nickel, performed There is very little margin for error.” in an ultra-modern electroplating Werner adds that Gleason Cutting electroless facility; and Tools’ ability to consistently produce nickel • Full-profile grinding of a coupon by these kinds of results wheel-to-wheel the finished wheel and final CMM enables the company to do what few in plating inspection of the profiled coupon, the electroplating industry would dare: provides a with verified wheel profile and furnish customers with a guarantee of expected K-chart results furnished quality, accurate estimates of tool life more uniform with every wheel. (the number of gears that can be pro- thickness duced), and recommendations on feeds and speeds to achieve optimum and higher Single Layer, Multiple Benefits performance. hardness The advantages of using single layer CBN Werner attributes much of the com- (or diamond) plated grinding wheels are pany’s success to its willingness to of the well-known. The single layer structure— invest in all of the resources needed to nickel CBN or diamond crystals of a specified control the production of these prod- size bonded to the wheel profile in a ucts in house. This includes: plating.” thin layer of nickel—is considerably harder than ferrite and other conven- • The use of advanced CNC equipment • Inspection of the core and its profile tional abrasives. It also offers the most for blanking, turning, heat treating, after finish grinding using super-accu- compressive strength, best wear resist- and finish grinding of the A2 steel rate computer-driven Coordinate ance, and highest heat conductivity, all body (called the core)—all done in Measuring Machines (CMM); in an open structure that facilitates chip accordance with ISO 9001 • Application of a single layer of clearance at even the heaviest stock International Quality Standards; abrasive CBN or diamond crystals removal rates. Yet creating a CBN single

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Contact us today for a prompt price quote ASH GEAR&SUPPLY on any special orders, materials and coatings Our experienced sales staff is ready to match your tooling requirements to a new or used product on our shelf, whether it's a hob, shaper, broach, you may require. 104 bevel generator or single cutter. We stock Premium Materials, Class AA-D, and Special Coatings. With 35,000 sq. ft. of gear cutting tools for SALE or RENT, you are sure to find AGMA standard as well as unique tooling to cut your job.

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gearsolutionsonline.com • JULY 2003 • GEAR SOLUTIONS 29 Program Means 21-day Deliveries Shaper-Cutter Line Expands with Form Grinding Capability Gleason has introduced a new “PDQ” program which delivers gear hobs of all sizes, Gleason has greatly expanded its capacity to produce the gear industry’s broadest, materials, and designs in just 21 days. Gear, involute spline, straight-sided serration, most complete line of gear-shaper cutters with the installation of new CNC form grinding parallel key spline, roller chain sprocket hobs, and even certain radial feed worm gear equipment at its Rockford, Illinois, facility. The Gleason shaper-cutter line is now available designs are just a few of the most common hobs now available as part of the PDQ in size ranges from 1.2 to 64 DP, with no limit on the number of teeth, and ground to Program. The program also accommodates customer requests for any popular high- Class 5 tolerances (DIN AA). The use of the new CNC form-grinding technology also enables speed steel, virtually any feature, and using the latest TiN, TiCN, and TiAlN coatings. Gleason to fulfill customer requirements for small shanks and special forms, and all A similar program also exists for Gleason’s gear-shaper cutters. with much higher levels of accuracy as compared to typical manual machine processes.

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30 GEAR SOLUTIONS • JULY 2003 • gearsolutionsonline.com layer with anything approaching the precision Single-layer CBN plating needed to achieve the tol- offers the most compressive erances and surface finishes found on today’s gear strength, best wear resistance, profiles can’t be done and highest heat conductivity, without the special technology and expertise all in an open structure that found in Gleason Cutting facilitates chip clearance at Tools’ plating facility. “CBN and diamond even the heaviest stock abrasive crystals are avail- removal rates. able in many sizes, from an average diameter of 35 microns (0.0014”) for 400/425 USA MESH, to 76 microns (0.0030”) for 20/30 USA MESH,” Werner explains. “However, if you were to simply apply, say, a 50/60 MESH crystal size right off the shelf, the deviation in crystal size would be enough to ultimately throw the wheel profile out of tolerance. So we employ a unique method to more precisely control their size and shape.” Gleason Cutting Tools has developed a system of “quarter sieving,” or “sub sieving” the crystals prior to the electroplating process. The crystals are put through a series of high quality electroformed sieves, ultimately ensuring that the particle-to-particle size separation in a single layer is within just five microns (0.0002”). This is just one of a whole series of steps that Gleason Cutting Tools continued on page 38 >> believes are required to ensure that the wheel ultimately produces the

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gearsolutionsonline.com • JULY 2003 • GEAR SOLUTIONS 31 R.P. Machine Enterprises, Inc. is one of the largest stocking gear dealers in the United States. We specialize in the buying and selling of gear machinery.

Our contacts are worldwide. We buy entire plants or individual machines. THE MAJORITY OF WHAT WE ADVERTISE, WE OWN.

Visit us at Gear Expo 2003 Booth #101 325 N. Miller Ave. / Statesville, NC 28677 / www.rpmachine.com (704) 872-8888 • Fax (704) 872-5777 / [email protected] MACHINERY

Alpha Gear & Machine, Inc. — Ref #100 New England Gear — Ref #105 Phone #:519-650-0943 •Fax #:519-650-7457 Phone #:860-223-7778 • Fax #:860-223-7776 Email: [email protected] Email: [email protected]

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Havlik International Machinery Inc. — Ref #102 Reliable Sales Company — Ref #107 Phone #:519-624-6240 • Fax #: 519-624-4119 Phone # 248-852-1116 • Fax #:248-852-1140 Email: [email protected] • Website: www.havlik-machinery.com Email: [email protected] Island Machinery Service — Ref #103 Repair Parts, Inc. — Ref #108 Phone # 843-681-9697 • Fax #: 843-342-2049 Phone #:815-968-4499 • Fax #:815-968-4694 Email: [email protected] • Website: www.island-machinery.com Email: [email protected] • Website: www.repair-parts-inc.com

Mohawk Machinery, Inc. — Ref #104 Contact Gear Solutions at 800-366-2185 to list your Phone: 800-543-7696 • Fax: 513-771-5120 Machines, Services and Tooling! Email: [email protected] • Website: www.mohawkmachinery.com

GEAR ACCESSORIES, PARTS & TOOLING DAVID BROWN Model #MT-60, 60” Diam, New ‘60 REF#106 BARBER-COLMAN Model #14-15, Dbl Thrd w/new Hydr Sys, Yr G&E Model #120H, 1/2 DP, 42” Face, Yr ‘94 REF#106 ‘65 REF#108 FELLOWS Model #10-4/10-2, All parts available REF#105 G&E Model #60S-2, 1 DP, 72" Diam, 38" Face, Yr ‘80 REF#106 BARBER-COLMAN Model #14-15, “As-Is”, Yr ‘65 REF#108 Tilt tables for 10-2/10-4, Qty 2 REF#105 G&E Model #72H, 70” Diam, 24” Length, Yr ‘45 REF#106 BARBER-COLMAN Model #14-15, Dbl Thrd Mach, Yr ‘66 REF#108 GEAR HOBBERS HURTH Model #KF-32A, 15" Diam, 59" Face, Yr ‘67 REF#106 BARBER-COLMAN Model #14-15, Dbl Thrd Mach w/hydr, Yr ‘66 REF#108 TOS Model #FO-10, 1000mm, Yr ’66, Overhaul ‘89 REF#102 KOEPFER Model #135, 3” Diam, 3” Face, Yr ‘60 REF#106 BARBER-COLMAN Model #14-15, Dbl Thrd Mach, “As-Is”, Yr ‘66 TOS Model #FO-10, Gear Hobbing Mach, Overhaul ‘90 REF#102 KOEPFER Model #173B, 6” Max Diam, 2 Axis Control, Yr ‘97 REF#106 REF#108 TOS Model #OFA-32A, Gear Hobbing Machine, Yr ‘89 REF#102 LEES BRADNER Model #SH, 8" Diam, 54" Face, Yr ‘50 REF#106 BARBER-COLMAN Model #14-15, Dbl Thrd Mach, Yr ‘66 REF#108 TOS Model #OFA-71A, Gear Hobbing Machine, Yr ‘86 REF#102 LEES BRADNER Model #HH, 15" Diam, 59" Face, Yr ‘77 REF#106 BARBER-COLMAN Model #14-15, Dbl Thrd Mach, Yr ‘67 REF#108 TOS Model #OFA-32A, Gear Hobbing Machine, Yr ‘86 REF#102 LIEBHERR Model #LC-183, 6 Axis, 8" Diam, 10" Face, Yr ‘98 BARBER-COLMAN Model #14-15, Sgl Thrd Mach, Yr ‘72 REF#108 GEAR HOBBERS NC & CNC REF#106 GEAR HOBBERS, VERTICAL LIEBHERR Model #LC-502, 6 Axis, 20" Diam, 16" Face, New ‘87 BORAS Helical Gear Hobber REF#101 REF#106 TOS Model #OFA32A, Auto, New, 20”x5”, Yr ‘88 REF#100 TOS Model #OFA-32, CNC, 840 Sinumetric, Year ‘02 REF#102 LIEBHERR Model #L-902, 3 Axis, 36” Diam, 32” Face, Yr ‘84 TOS Model #OFA71A, Auto, New, 29”x18”, Yr ‘88 REF#100 TOS Model #OFA-32, CNC, 6 Axis, Diam 320 mm, New REF#102 REF#106 TOS Model #FO16, 63”x22”, Set-ups, Sgl Index, Tang & Std Heads REF#100 TOS Model #OFA-75, CNC, 6 Axis, Diam 800 mm, New REF#102 LIEBHERR Model #L-1202, 6 Axis, 49" Diam, 24" Face, Yr ‘78 TOS Model #OFA-100, CNC, 6 Axis, Diam 1000 mm, New REF#102 REF#106 LIEBHERR Model #L400 REF#100 GEAR HOBBERS, HORIZONTAL MITSUBISHI Model #GA-40, 16” Cap, w/Fanuc 6M Control New TOS Model #FO10, 40” Capacity, Std & Tang Heads REF#100 ‘86 REF#106 CLEVELAND Model #1883, 7” Diam, w/Ext Hgt Tailstock REF#104 MIKRON Model #A21/2, 1-9/16” Diam, 26 DP, Hopper Feed REF#104 LEES BRADNER Model #7HD, 8” Diam, 4 DP, Auto Hobshift REF#104 BARBER COLMAN Model #2-1/2-4, 4” face, Var Speed Drive REF#104 MITSUBISHI Model #GB-100, 40" Diam, 20" Face, New ‘96 REF#106 NEWARK Horiz. Pinion Hob, 18" Diam, 112" Face REF#106 CLEVELAND Model #1886, 8” Diam, 4 DP, Sine Bar Att REF#104 BARBER COLMAN Model #3, 5” Diam, 10” Axial Travel, With or PFAUTER Model #RS00S, 8”/10” Diam, 6 DP, Diff REF#104 w/o Diff REF#104 OVERTON Model #HD-400, 15.7” Diam, 12” Face, Yr ‘80 REF#106 LIEBHERR Model #L-200, 10” Diam, Hvy-Duty Hi-Speed, Yr ‘79 PFAUTER Model #PE-150, 6 Axis, 6" Diam, 6" Face, New ‘80s BARBER COLMAN Model #6-16, 3-Thread, Turret Tailstock, Yr REF#104 ’63 REF#104 REF#106 LIEBHERR Model #L-252, 10” Diam, Crowning, Spur only REF#104 BARBER COLMAN Model #Type D, 14” Diam, 15” Axial Travel, PFAUTER Model #P-250H, 32” Diam, 3” Face, Yr ‘81 REF#106 LIEBHERR Model #L-301, 12” Diam, 2-Cut, Crowning REF#104 3.5 DP, Diff REF#104 PFAUTER Model #P-400, 5 Axis, 16” Diam, 12” Face, Yr ‘95 REF#106 CLEVELAND Model #CR-300, 12” Diam, Crowning, 2-Cut, New BARBER COLMAN Model #14-15, Hobshift, 6-Thrd Index REF#104 SCHLESS Model #1RF-10, 55" Diam, 102" Face, Yr ‘50’s REF#106 REF#104 BARBER COLMAN Model #16-36, Multicycle, 2-Thrd Index, Reb SYKES Model #H-160, 4 Axis, 6" Diam, New ‘93 REF#106 KASHI FUJI Model #KS-14, 14” Diam, Crowning, Auto Cycle, 4 REF#104 TOS Model #OFA-32, 6 Axis, 12.6” Diam, 12” Face, New REF#106 DP REF#104 BARBER COLMAN Model #16-36, Diff, 2-Thrd Index, 36” Axial TOS Model #OFA-75, 6 Axis, 32" Diam, 18" Face, New REF#106 PFAUTER Model #P-403, 18” Diam, 2-Cut, Full Mach Encl, New Travel REF#104 WANDERER Model #GF32N, 13” Diam, 200” Face, Yr ‘80 REF#106 ‘81 REF#104 BARBER COLMAN Model #16-56, Hobshift, Dbl Thread Index, PFAUTER Model #P-630, 24” Diam, Diff, Infeed, New ‘69 REF#104 Recon REF#104 BARBER-COLMAN Model #10-20, Dbl-cut, 2 Thd Index REF#107 BARBER-COLMAN Model #14-15, Dbl Thrd Mach, Fact Reb ‘49 LIEBHERR Model #L-652, 24” Diam, Diff, Infeed, Crowning, 2- BARBER-COLMAN Model #6-10, 2 Axis, 6” Diam, 10” Face, New cut, Yr ‘76 REF#104 REF#108 ‘96 REF#106 BARBER COLMAN Model #25-30, 30” Face Width, 2.5 DP REF#104 BARBER-COLMAN Model #3 (6-10), Sgl. Start Precision Worm BARBER-COLMAN Model #14-15, Dbl Thrd Mach, Fact Reb ‘51 REF#108 PGM STAEHELY Model #SH-651, 25.5” Diam, Univ Hobhd, Yr REF#106 ‘82 REF#104 BARBER-COLMAN Model #14-15, Dbl Thrd Mach, Fact Reb ‘53 BARBER-COLMAN Model #3 (6-10), Differential REF#106 PFAUTER Model #P-900, 36” Diam, Diff, 2.5 DP REF#104 REF#108 BARBER-COLMAN Model #6-10, 6” Diam, 10” Face, Yr ‘49 REF#106 LIEBHERR Model #L-901, 36” Diam, Crowning, Auto-2-Cut, Diff, BARBER-COLMAN Model #6-16, 6 Start Worm, Yr ‘72 REF#106 BARBER-COLMAN Model #14-15, Sgl Thrd Mach, Yr ‘55 REF#108 Yr ‘74 REF#104 BARBER-COLMAN Model #14-15, 14" Diam, 15" Face REF#106 BARBER-COLMAN Model #14-15, Dbl Thrd Mach w/dwell, Yr ‘55 KASHIFUGI Model #KR-1000, 40” Diam, Diff, Infeed REF#104 REF#108 BARBER-COLMAN Model #14-30, 30” Diam, 14” Axis, Yr ‘67 REF#106 MODUL Model #ZFWZ-10, 48” Diam, Full Universal, New ‘83 REF#104 BARBER-COLMAN Model #16-16, Multi-Cycle, Dual Thrd Worm BARBER-COLMAN Model #14-15, Dbl Thrd Mach w/hyd tailctr, G&E Model #48H, 48”/72” Diam REF#104 Yr ‘56 REF#108 REF#106 G&E Model #48HWD, 48” Diam, Worm Driven Hobhead REF#104 BARBER-COLMAN Model #14-15, Dbl Thrd Mach, Yr ‘62 REF#108 BARBER-COLMAN Model #16-36, 24” Diam, Yr ‘68 REF#106 G&E Model #48HWD, 48” Diam, Worm Driven Hobhead, Yr ‘72 BARBER-COLMAN Model #16-56, 16” Diam, 56” Face, Yr ‘68 BARBER-COLMAN Model #14-15, Dbl Thrd Mach, Yr ‘62 REF#108 REF#104 REF#106 BARBER-COLMAN Model #14-15, Dbl Thrd Mach, “As-Is”, Yr ‘63 LIEBHERR Model #L-1500, 60” Diam, Sgl-Index, Diff, Yr ’68 BARBER-COLMAN Model #11x48, 11" Diam, 48" Face, Yr ‘68 REF#108 REF#104 REF#106 BARBER-COLMAN Model #14-15, Dbl Thrd Mach, “As-Is”, Yr ‘65 G&E Model #72HWD, 72” Diam, 1.25 DP, Diff, Infeed, Sgl-Index BARBER-COLMAN Model #22-15, 22” Max OD, 4DP REF#106 REF#108 REF#104

gearsolutionsonline.com • JULY 2003 • GEAR SOLUTIONS 33 SCHIESS Model #RF-30E, 125”/196”Diam, Hvy Duty w/Gashing G&E Model #60S2, 60” Diam, 3-Axis CNC, Spur/Bevel REF#104 MAAG Model #SH-350/500, Ext Gen/Int Gashing Heads, New Hd REF#104 G&E Model #60S, 72” Diam, Yr ‘52/’64 REF#104 ‘60’s REF#106 G&E Model #16H, Univ. Head, Yr ’62, Rebuilt ‘80’s REF#106 GEAR LAPPERS MICHIGAN Model #18106, 10” Diam, 4.5” Face REF#106 G&E Model #24H, Univ. Head, Infeed, Yr ‘50’s REF#106 TOS Model #OHA-50A, 20” Diam, 5” Face, Yr ‘85 REF#106 GLEASON Model #503, 10.5” Diam, Hypoid, 90-Degree REF#104 G&E Model #36HWD, Differential, New ‘40’s REF#106 GEAR SHAPERS, NC & CNC GLEASON Model #17, 16” Diam, Lapper/Tester, 90 Degree REF#104 G&E Model #48HWD, Defferential, New ‘50’s REF#106 FARRELL SYKES Model #2A Herringbone Gear Shaper REF#101 G&E Model #60S, 72" Diam, 16" Face REF#106 GEAR SHAPERS FELLOWS Type 6 Gear Shapers REF#101 G&E Model #84/96H, High Stanchion, Differential REF#106 TOS Model #OHA50A, Auto, New 20” x 5”, Yr ‘88 REF#100 MAAG Model #SH180/300 Shaper w/Internal Att. REF#102 HAMAI Model #120, 4.8" Diam, 4" Face, Yr ‘70 REF#106 MAAG Model #SH100, w/JV100 REF#100 TOS Model #OHA-16, CNC, 5 Axis, Diam 160 mm, New REF#102 HURTH Model #WF-280, 11' Diam, 10" Face, Yr ‘85 REF#106 MAAG Model #SH75C, Sub Table, Steady, Nice REF#100 TOS Model #OHA-32, CNC, 5 Axis, Diam 320 mm, New REF#102 JEIL Model #JDP-2, 26” Max Hob Cap, 4DP REF#106 SLOTER HOV 63 24” Stroke, Dividing Table, Feeds & Rapids REF#100 TOS Model #OHA-50, CNC, 5 Axis, Diam 500 mm, New REF#102 JEIL Model #JDH-34, 31" Diam, 13" Face, Yr ‘01 REF#106 TOS Model #OHA-12A, Shaping Machine, Yr ‘02 REF#102 LORENZ Model # MCS-40, 20” Diam, 6” Face, 6 Axis Ret LIEBHERR Model #L-1200, 49" Diam, 22" Face, New ‘75 REF#106 TOS Model #OHA-12A, Shaping Machine, Yr ‘84 REF#102 w/Warr, New ‘90 REF#104 LIEBHERR Model #L-301, 12" Diam, 9" Face, Yr ‘74 REF#106 TOS Model #OHA-50A, Shaping Machine, Yr ’86, Overhaul ‘03 LIEBHERR Model #WS-501, 20” Diam, 5” Face, 5 Axis SIEMENS LIEBHERR Model #L-400, 16” Diam, 10” Face, Yr ‘68 REF#106 REF#102 840D, New ‘89/’03 REF#104 LIEBHERR Model #L-401, 16” Diam, 8" Face, Yr ‘70’s REF#106 TOS Model #OHA-50A, Shaping Machine, Yr ‘90 REF#102 FELLOWS Model #50-8, 51” Diam, Sgl Axis NC, 3 Axis PLC, New LIEBHERR Model #L-402, 16" Capacity, New ‘77 REF#106 MAAG Model #SH75, Shaping Machine, Yr ’53, Overhaul ‘03 REF#102 ‘76 REF#104 LIEBHERR Model #L-652, 25” Diam Cap, 19.7” Face, 2DP REF#106 MAAG Model #SH180/30, Yr ’53, Overhaul ‘03 REF#102 MAAG CNC Retrofit Pkgs for Both Crank-Type & Screw Type LIEBHERR Model #L-900, 36” Diam, Yr ‘68 REF#106 FELLOWS Model #3, 3” Diam, Fine Pitch, w/Change Gears REF#104 Machines REF#104 LIEBHERR Model #L-901, 35” Diam, 15” Face REF#106 FELLOWS Model #4AGS, 6” Diam, 2” Riser, 2” Face REF#104 FELLOWS Model #10-4/10-2, Qty 150 REF#105 LIEBHERR Model #L-902, 36" Diam, 25" Face, Yr ‘83 REF#106 FELLOWS Model #4GS, 6” Diam, 2” Raising Block, 2” Face REF#104 HYDROSTROKE Model #50-8, Qty 2 REF#105 OVERTON Model #HD-400, 15.7" Diam, Yr ‘80 REF#106 FELLOWS Model #725, 7” Diam, 1.5” Face REF#104 HYDROSTROKE Model #20-8, Qty 5 REF#105 PFAUTER Model #P-251 & P-253, 10" Diam, 9" Face, Yr ‘83 REF#106 FELLOWS Model #8AGS, 8” Diam, 2” Face REF#104 HYDROSTROKE Model #FS630-125, Qty 1 REF#105 PFAUTER Model #P-400 & #P-403, 16" Diam, Yr ‘83 REF#106 FELLOWS Model #10-2, 10” Diam, 2” Face REF#104 HYDROSTROKE Model #FS400-90, Qty 2 REF#105 PFAUTER Model #P-630, 24” Capacity, Rebuilt ‘78 REF#106 MICHIGAN Model #18106, 14” Diam, “Shear Speed” REF#104 FELLOWS Model #20-4, Qty 6 REF#105 PFAUTER Model #P-900, 36” Diam, 15" Face, New ‘60 REF#106 MITSUBISHI Model #SH-630, 26.8” Diam, 8” Face, 3.2 DP, New FELLOWS Model #48-8Z, Qty 1 REF#105 PFAUTER Model #RS-00, 10" Diam, 7” Face, New ‘60’s REF#106 ‘88 REF#104 36” Shapers, 14” Throat Risers, 53” of swing, Qty 3 REF#105 PFAUTER Model #RS-1, 29" Diam, 12" Face, New ‘50’s REF#106 MAAG Model #SH-75K, 29.5” Diam, Std & DS-75 Cutter-Holders FELLOWS Model #4AVS, 4” Stroke, Spur Guide, Auto Cutter, REF#104 RPM Model #AD-616, 6" Diam, 16" Face, New REF#106 Riser REF#107 FELLOWS Model #50-8, 51” Diam, “Hydrostroke”, 8” Face REF#104 SCHIESS Model #RF40/50S, 197" Diam, 79" Face, Yr ‘73 REF#106 GEAR DEBURRERS MAAG Model #SH-250/300, 121.3” Max Diam, 26” Face Width PFAUTER Model #PA300, 2-cut, Diff, Hob Shift REF#107 REF#104 CROSS Model #55, Deburrer, 18” Diam, Yr ‘52 REF#106 GEAR HOBBERS, VERTICAL, N/C & CNC MAAG Model #SH350/500, 200” Diam, w/JVE Internal, DS Swvl HURTH Model #ZK-5, Twin Spindle Chamfering & Deburrer REF#106 PFAUTER Model #PE-150, 6” Diam, 6-Axis CNC, New ‘86 REF#104 Hd REF#104 HURTH Model #ZK-10, 16” Diam, Yr ‘60’s REF#106 PFAUTER Model #PA-210, 10” Diam, 3-Axis CNC, Qty 2 REF#104 BARBER-COLMAN Model #HD-200, 2.75” Stroke, New ‘84 REF#106 REDIN Model #18, 28” Diam, New ‘90’s REF#106 PFAUTER Model #PE-750, 30” Diam, 6-Axis CNC Universal, New FELLOWS Model #10-2 & 10-4, 10" Diam, 2”-4" Face, Rebuilt ‘03 REDIN Model #24, 25” Diam, Yr ‘95 REF#106 ‘00 REF#104 REF#106 GEAR CHAMFERING FELLOWS 100”, 12” Stroke, Retrofitted in ‘98 REF#106 LIEBHERR Model #L-902, 36” Diam, 3-axis CNC Universal REF#104 CROSS Model #75, Chamferer, 10” Diam, New ‘52 REF#106 FELLOWS Model #FS-400-90, 5 Axis, 16” Diam, 4” Face, Yr ‘90 LIEBHERR Model #L-1801, 72” Diam, 6-Axis CNC Universal REF#104 GLEASON Model #GTR-250VG, 5-Axis CNC, 10” Diam REF#106 REF#106 SAMPUTENSILI Model #SCT-3, 14” Diam, New ‘82 REF#106 GEAR CUTTER SHARPENERS (incl. CNC) FELLOWS FS-630-200, 24” Diam, 8” Face, Yr ‘95 REF#106 SAMPUTENSILI Model #SCT-3, 14” Diam, New ‘97 REF#106 MAAG Model #WS, 2 Rack Cutter Sharpener REF#100 FELLOWS Model #50-8, 51.18” Int/Ext Diam., Yr ‘86 REF#106 SAMPUTENSILI Model #SCT113, 14” Diam, Yr ‘97 REF#106 BARBER-COLMAN 10x10 Hob Sharpeners, Qty 2 REF#101 FELLOWS Model #3-1, 3” Diam, 1” Face, Yr ‘62 REF#106 SAMPUTENSILI Model #SM2TA, 10” Diam, New ‘95 REF#106 BARBER-COLMAN 4x4 Hob Sharpeners, Qty 2 REF#101 FELLOWS Model #4AGS/#4GS, 6” Diam, 2” Face, Yr ‘68 REF#106 SAMPUTENSILI Model #SM3TA, 10” Diam, Yr ‘89 REF#106 MIKRON Model #121, 2.1” Diam, Hob Sharpener REF#104 FELLOWS Model #6, 15” Diam, 3” Face, Yr ‘70’s REF#106 SAMPUTENSILI Model #SU-41/370-1, 15” Diam, New ‘90’s REF#106 BARBER COLMAN Model #2 2 1/2-2, Straight Flute Hobs REF#104 FELLOWS Model #612A, 18” Diam, 5” Face, Yr ’40-60’s REF#106 WERA Model #DRT-250, CNC Pointer, 9.84” Diam, New ‘97 REF#106 BARBER COLMAN Model #3-4/4, Index Plates REF#104 FELLOWS Model #615A, 18” Diam, 5” Face, Yr ’40-60’s REF#106 BARBER COLMAN Model #6-5, 5” Face, Yr ‘57-70 REF#104 FELLOWS Model #645A, 18” Diam, 3” Face, Yr ‘40 REF#106 GEAR HONERS MIKRON Model #A62, 6” Diam, Auto Dressing, Coolant REF#104 FELLOWS Model #6A, Adj Helical, 15” Diam, 3” Face, Yr 70’s FASSLER Model #K-400, 12.6” Diam, 12” Stroke, New ‘95 REF#106 KLING Model #AGW/230, 10” Diam, Index Plates REF#104 REF#106 FELLOWS Model #4 Fine Pitch, 4” Diam, Yr ‘48 REF#106 KLING Model #SNC-30, 12” Diam, CNC Hob Sharp, New ‘84 REF#104 FELLOWS Model #7/7A Face Cutter, 7” Diam REF#106 NAT BROACH Model #GHH/12, Pneumatic Centers, Crowning KLING Model #AGW/421, 16” Diam, Coolant, Index Plates REF#104 FELLOWS Model #7/7A, 7” Diam, 1.5” Face, Yr ‘43 REF#106 REF#107 KLING Model #ZS/231, Wheelhd for AGW-232, 230, 231, 301, FELLOWS Model #712, 7” Diam, 1.5” Face, Yr ‘48 REF#106 GEAR SHAVERS (incl. CNC) 421 REF#104 FELLOWS Model #7125 & 7125A, 7” Diam, 1.5” Face, Yr ‘50’s RED RING Shaver 12" REF#101 REF#106 FELLOWS Model #6SB, 6” Diam, Helical, 50° Helix Angle REF#104 RED RING Model #GCY-12, 12” Diam, 9” Cutter-Head REF#104 FELLOWS Model #72, 7” Diam, 1.5” Face, Yr ‘48 REF#106 MAAG Model #WS/3, Rack-Type REF#104 RED RING Model #GCU-18, 18” Diam, Crowning REF#104 FELLOWS Model #725, 7” Diam, 1.5” Face, Yr ‘50’s REF#106 GLEASON Model #2JST, 6” Diam, Straight Bevel Coniflex REF#104 RED RING Model #GCX-24, 24” Diam, 12” Cutter-Head REF#104 FELLOWS Model #75, 7” Diam, 1.5” Face, Yr ‘50’s REF#106 GLEASON Model #7, 6” Diam, Spiral Bevel Cutter REF#104 RED RING Model # GCJ-36/60, 60” Diam, 12” Cutter-Head REF#104 FELLOWS Model #8AGS, 8” Diam, 2” Face REF#106 GLEASON Model #13A, 18” Diam, Bevel REF#104 RED RING Model #GF-300, 7 Axis, 12” Diam, Yr ‘90 REF#106 FELLOWS Model #10-2, 10” Diam, 4” Face, Yr ‘82 REF#106 KLING Index Plates and Arbors REF#104 RED RING Model #GCX-24, 3”-24” Pitch Diam, Yr ‘74 REF#106 FELLOWS Model #10-4, 10” Diam, 4” Face, Yr ‘96 REF#106 ARTER Model #A-12, 12" Rotary Surface Grinder REF#106 RED RING Model #GCU-8, 8” Diam, Yr ‘82 REF#106 FELLOWS Model #18-5, 18” Diam, 5” Face, Yr ‘74 REF#106 BARBER-COLMAN Model #6-5 & #4-4 REF#106 RED RING Model #GCU-12, 12 Diam, Yr ‘91 REF#106 FELLOWS Model #20-4, 20” Diam, 4” Face, Yr ‘75 REF#106 BARBER-COLMAN Model #4-4, 4" Diam, 4" Long, Yr ‘51 REF#106 RED RING Model #GCY-12, 12” Diam, 6” Stroke, Yr ‘68 REF#106 FELLOWS Model #36-6, 36” Diam, 6” Face, Yr ‘68 REF#106 BARBER-COLMAN Model #10-12, Dry Machine REF#106 RED RING Model #GCY-18, 18” Diam, 6” Stroke, Yr ‘64 REF#106 FELLOWS Model #36-6, 36” Diam, 6” Face, Yr ’51-55 REF#106 DAVID BROWN Model #MH-100, 149” Diam, 54” Length, Yr ‘60 NAT BROACH Model #GCU12/8, Up-Feed, Pneumatic Ctrs REF#107 REF#106 FELLOWS Model #36-8, 36” Diam, 8” Face, Yr ‘53 REF#106 NAT BROACH Model #GCY18, 12” Cutter Head, Crowning REF#107 FELLOWS Model #6SB, 6" Diam, 3" Long, Yr ‘60 REF#106 FELLOWS Model #36-8Z, 36” Diam, 9.5” Face, Yr ‘95 REF#106 GEAR GENERATORS, BEVEL, STRAIGHT HEALD Model #22, Rotary, 13" Diam, 12" Chuck REF#106 FELLOWS Model #120-8, 8” Stroke, Rebuilt ‘88 REF#106 KAPP Model #AS204GT, 10" Diam, New ‘82 REF#106 FELLOWS Model #185-8, 200” Diam, 9” Face, Yr ‘98 REF#106 GLEASON 28" Spiral Bevel Generator REF#101 KLING Model #SNC-30, CNC, 12" Diam, 18" Length, Yr ‘84 REF#106 FELLOWS Model #200, 8” Stroke, 200” Diam, Reb ‘88 REF#106 GLEASON Model #3”, 4.45” Diam, 2-Tool w/Segments & Gears KLING Model #AGW-30A, 11" Diam, 16" Length, Yr ‘62 REF#106 FELLOWS Model #645A, Several Available REF#106 REF#104 STAR Model #2 VHS-EZ, 6” Max Hob, New ‘73 REF#106 FELLOWS Model #Horiz.Z, 6” Stroke, New ‘50’s REF#106 GLEASON Model #710, 10” Diam, Coniflex REF#104 UTMA Model #LC-35-NC4, 10" Diam, 10" Length, New REF#106 LORENZ Model #LS-180, 4 Axis, 7” Max, New ‘87 REF#106 GLEASON Model #114, 16” Diam, Coniflex REF#104 STAR Model #VHS, 6”x6”, Coolant System, Vitrified Wheel LORENZ Model #MCS-60, 9 Axis, 40" Diam, 8" Face, Yr ‘91 REF#106 GLEASON Model #104 Coniflex, 8” Cone, Yr ‘58 REF#106 Grinding REF#107 LIEBH/LORENZ Model #WSC-1202, 48” Diam, 12” Face, Yr ‘90 GLEASON Model #12, 12” Cone, 3.5” Face, Yr ‘50’s REF#106 BARBER-COLMAN Model #6-5, Hydraulic Dresser,12 Index Plate REF#106 GLEASON Model #14 Coniflex, 12” Cone, 3.5” Face REF#106 REF#107 MAAG Model #SH-75C, 9” Stroke, Yr ‘65 REF#106 GLEASON Model #106, 4” Cone REF#106 GEAR CUTTERS, GASHERS (INCLUDING CNC) MAAG Model #SH-75K, 9” Stroke REF#106 GLEASON Model #114 Coniflex, 7” Cone, 2.5” Face REF#106 LIEBHERR #ET-1202, 48” Diam, 4-Axis CNC Ext Miller/Gasher MAAG Model #SH-100K, 47” Diam, 12” Face, Yr ‘60’s REF#106 GLEASON Model #116, 9” Cone REF#106 REF#104 MAAG Model #SH-180/300, 118” Diam., 17” Face, year 60’s REF#106 GLEASON Model #37, 26” Cone, 10” Face REF#106

34 GEAR SOLUTIONS • JULY 2003 • gearsolutionsonline.com GLEASON Model #54, 38” Cone, 17” Face REF#106 SYKES Model #VR-72, 72” Cut Length REF#106 FELLOWS Model #8, Microdex Tooth Spacing Checker, 80mm MIKRON Model #120.1 & #132.02, 1.6” Cone, Yr ’50-60’s REF#106 SYKES Model #VR-72B, 72” Cut Length REF#106 Recording REF#103 GEAR GENERATORS, HERRINGBONE SYKES Rack Shaping Package ‘78 REF#106 FELLOWS Model #4RL, 4” Diam, Comp Roll Checker REF#104 FELLOWS Model #12M, 12” Diam, Involute REF#104 FARREL SYKES Model #2A Herringbone Gear Shaper REF#101 GEAR QUENCHING PRESSES HOEFLER Model #EFR-401, 15.75” Diam, Lead & Involute REF#104 FARREL-SYKES Model #3C, 37” Diam, 8” Face, 30” LH/RH GLEASON Model #26, Quench Press, 10” Open REF#106 ILLINOIS Model #3412B-2C, 12” Diam, Involute REF#104 Guides REF#104 GEAR ROLLERS ILLINOIS Model #3424B-3C, 24” Diam, Involute REF#104 FARREL-SYKES Model #5B, 61” Diam, 18” Face REF#106 AC MARAND Model #340S, Spline Roller, 36” Rack, Yr ‘70’s REF#106 ILLINOIS Model #3712A-2C, 12” Diam, Tooth Space Comp REF#104 FARREL-SYKES Model #10A, 120” Diam, 24” Face REF#106 EX-CELLO Model #3225, Spline Roller, 24” Rack REF#106 ILLINOIS Model #3806, 6” Diam, 24”cc REF#104 SYKES Model #1A, 12” Diam REF#106 GEAR THREAD MILLERS, GRINDERS ILLINOIS Model #524, 36” Diam, Involute Profile Checker REF#104 GEAR GENERATORS, BEVEL, SPIRAL, HYPOID WANDERER Model #31Lx3000, Differential for Hobbing REF#100 MAAG Model #DAS-1, Composite REF#104 GLEASON 28" Spiral Bevel Generator REF#101 EXCELLO Model #39A, 9.5” Diam, 5” Length, Yr ‘60’s REF#106 MAAG Model #TML, Hand-Held Pitch Tester, 50–3 DP REF#104 GLEASON Model #16, 16” Diam, Finisher, Change Gears REF#104 HECKERT Model #ZFWVG, 10” Diam, 49” Length, Yr ‘99 REF#106 RED RING Model #GRH, 10.375” Max cc REF#104 GLEASON Index Plates for 11 & 22 Hypoid Rougher & Finisher PARKSON Model #30, Worm & Worm Wheel Att REF#104 REF#104 HANSON-WHITNEY, 10”x24” Univ Thread Mill REF#106 J&L Model #12X45, 12” Diam, 45” Length REF#106 HOEFLER Model #EMZ-402, 16” Diam, CNC Lead/Inv/Index, GEAR GRINDERS, NC AND CNC w/Warr REF#104 J&L Model #TG636, 7.5” Diam, 36” Length, Yr ‘42 REF#106 HOEFLER Model #EMZ-630, 24” Diam, CNC Lead/Inv/Index, REISHAUER Model #RZ-301AS, 13” Diam, Production CNC, New LEES BRADNER Model #LT, 9” x 54”, Yr ‘40’s REF#106 ’92 REF#104 w/Warr REF#104 LEES BRADNER Model #HT12X54, 12” Diam, New ‘50’s REF#106 SAMPUTENSILI Model #RI-370, 15” Diam, CNC Int/Ext, New ‘96 HOEFLER Model #EMZ-1001, 40” Diam, CNC Lead/Inv/Index, PFAUTER Model #SF-1, 13” Diam, 27” Length, Yr ‘50’s REF#106 REF#104 w/Warr REF#104 PRATT & WHITNEY Model #6X20 & #4.5X36, 6” Diam, 20” GLEASON Model HG-400 “Phoenix”, 16” Diam, CNC, New ‘91 KLING Model #PFSU-1600, 64” Diam, Lead/Inv/Spacking, Length REF#106 REF#104 w/Warr REF#104 REISHAUER Model #UL-900, 9” Diam, 18” Length, Yr ‘80’s REF#106 KAPP Model #VAS-531, 20” Diam, CNC Spur/Helical, New ‘91 KLING Model #PFSU-2500, 100” Diam, Lead/Inv/Spacing, REF#104 REISHAUER Model #US, 10” Diam, 36” Length, New ‘80’s REF#106 w/Warr REF#104 REISHAUER Model #RZ-801S, 30” Diam, CNC Spur/Hel, New ‘93 WANDERER Model #31LX3000, 8” Diam, 120” Length, Yr ‘60’s DAVID BROWN Model #24, 24”x36”, Worm & Worm Gear Tester REF#104 REF#106 REF#106 GLEASON Model # 130, 36” Max Diam, CNC Curvic Cplg, Comp GEAR HOB SHARPENING GLEASON Model #6, Lg Bevel Tester, 7.5” Diam REF#106 Reb REF#104 BARBER-COLMAN 10x10 Hob Sharpeners, Qty 2 REF#101 GLEASON Model #4, 3” Diam, 2.5” Max Ctr Distance REF#106 GEAR GRINDERS BARBER-COLMAN 4x4 Hob Sharpeners, Qty 2 REF#101 GLEASON Model #13, Universal Spiral Bevel Tester, 13” OD REF#106 MAAG 72” Gear Grinder REF#101 BARBER-COLMAN Model #2 1/2-2, Wet Mach Man Fd, Yr ‘64 KLING Model #PFSU-1200, 48” Diam, 1.27 DP, 43” CC REF#106 MAAG 32" Gear Grinder REF#101 REF#108 NAT BROACH Model #GSJ-12, Gear Noise Tester, Yr ‘50’s STANKO 24" Gear Grinder, New REF#101 BARBER-COLMAN Model #2 1/2-2, Wet Mach w/auto Feed, Yr ‘66 REF#108 REF#106 HORFLER 800 Millimeter Gear Grinder REF#101 BARBER-COLMAN Model #6-5, Wet w/Auto Dress & Sparkout, PARKSON Model #15N, Gear Rolling Tester, 15” Diam REF#106 NILES 800 Millimeter Gear Grinder REF#101 Yr ‘53 REF#108 FELLOWS Model #12H/12M, Lead/Involute Checker, REF#107 REISHAUER ZB Gear Grinder REF#101 BARBER-COLMAN Model #6-5, Wet w/Auto Dress & Sparkout, ITW Model #3412-A-3C/3912-A-3C, Lead/Involute Checker MAAG Model #HSS60/80BC, Horiz REF#101 Yr ‘53 REF#108 REF#107 MAAG Model #HSS60BC, Horiz REF#101 BARBER-COLMAN Model #6-5, Wet w/Auto Dress & Sparkout, GEAR S/N TESTERS, BEVEL, SPIRAL, HYPOID CHINESE version of MAAG HSS60CS, YM7132A (never used) Yr ‘53 REF#108 GLEASON Model #6, 7.5” Diam, Angular REF#104 REF#101 BARBER-COLMAN Model #6-5, Wet w/Auto Dress & Sparkout, GLEASON Model #527, Spiral Bevel Cutter Insp Mach REF#104 MAAG Model #SHS150, Vertical REF#101 Yr ‘56 REF#108 GLEASON Model #61, 90” Diam, Angular Bevel Tester REF#104 MAAG Model #PH60, Involute & Lead Checker w/accessories BARBER-COLMAN Model #6-5, Wet w/Auto Dress & Sparkout, REF#101 Yr ‘62 REF#108 GEAR CHECKERS GLEASON Model #28 Spiral Bevel Machine REF#101 BARBER-COLMAN Model #6-5, Wet w/Auto Dress & Sparkout, GLEASON Model #15, 15” Diam, Blank REF#104 RUSSIAN (Niles Type) Type 5M841 (never used) REF#101 Yr ‘62 REF#108 GLEASON Model #D-15S, Spiral Bevel Cutter REF#104 HOEFLER – Rebuilt in 1995 Class 12 Gears 800 mm REF#101 BARBER-COLMAN Model #6-5, Wet Mach, Yr ‘63 REF#108 GEAR TOOTH CHAMFERING MACHINES REISHAUER Model #ZA w/several accessories REF#101 BARBER-COLMAN Model #6-5, Wet w/Auto Dress & Sparkout, CROSS Model #75, 10” Diam REF#104 NILES Model #ZSTZ 10, Yr ‘79 REF#102 Yr ‘66 REF#108 CROSS Model #65, 10” Diam, 9” Face, 4 DP REF#104 MAAG Model #HSS-30A, 11.8” Diam, Spur REF#104 BARBER-COLMAN Model #6-5, Wet w/Auto Dress & Sparkout, Yr ‘66 REF#108 SAMPUTENSILI Model #SCT-3, 13.78” Diam, Yr ‘97/98 REF#104 FELLOWS REISHAUER Model #12, 6.75” Face, Yr ’62/’65 REF#104 BARBER-COLMAN Model #6-5, Wet w/Auto Dress & Sparkout, WERA Model #DRT-250, 9.8” Diam, CNC REF#104 REISHAUER Model #AZA-K, 12” Diam, SPA Diamond Disc, New Yr ‘69 REF#108 ’79 REF#104 REDIN Model #24, 28” Diam, CNC Twin Spindle Deburring, Yr BARBER-COLMAN Model #6-5, Wet w/Auto Dress & Sparkout, ‘90 REF#104 MAAG Model # SD-32X, 12.6” Diam, 9.8” Face, T&R REF#104 Yr ‘69 REF#108 OKAMOTO Model #SHG-360, 14” Diam, FAESSLER “DSA” MISCELLANEOUS BARBER-COLMAN Model #10-12, Wet w/Auto Dress & Sparkout, Diamond Disc REF#104 LATHES Yr ‘65 REF#108 DETROIT GEARGRIND Model #GGI-16X3A, 16” Diam, Internal JAMISON Small Lathe 10" Chuck, 12" Over Carriage REF#101 BARBER-COLMAN Model #4HS, Dry Mach w/mist System, Yr Spur REF#104 ‘51 REF#108 BOYE & EMMES Lathe 12" Chuck, 12" Over Carriage REF#101 HOEFLER Model #H-500, 20” Diam, Spur/Helical, Crowning T&R, BARBER-COLMAN Model #4HS, Dry Mach, Yr ‘52 REF#108 SIDNEY Lathe Model #TV 4334 15" Chuck, 22" Swing REF#101 New ‘80 REF#104 BARBER-COLMAN Model #10-12, Wet w/Auto Dress & Sparkout, PUTNAM Lathe, 54" Chuck, 61" Swing, 246" Between Centers HOEFLER Model #H-1000E 40” Diam, Spur/Helical, Crowning, Fact Reb ‘82 REF#108 REF#101 New ‘88 REF#104 BARBER-COLMAN Model #10-12SDHM, Dbl Thrd Mach, Yr ‘42 MONARCH Engine Lathe, 15" Chuck, 20" Swing, 12" Over MICHIGAN Model #MHGGI-FA, 40” Diam x 24” Face, Spur/Hel/ REF#108 Carriage REF#101 Int/Ext REF#104 SAWS/OTHER METAL CUTTING MACHINES REISHAUER Model #DS, Diamond Lapping Machine REF#104 GEAR TESTERS HOFLER Model #H-500, 20” Diam, Yr ‘79 REF#106 FELLOWS Model #12H, Lead checker, 12” Diam, w/14” Base Ext HYUNDAI Model #HIT18S, CNC Lathe, Yr ‘98 REF#102 HOFLER Model #H-630, 25” Diam, Yr ‘80 REF#106 REF#103 ZPS Zlin Model #S50, CNC Lathe, Yr ‘98 REF#102 MAAG Model SD-36-X, 14” Diam, Yr ‘89 REF#106 FELLOWS Model #12H, Lead checker, 12” Diam, w/ Standard TOS Trencin Model #SN50B/1500, Centre Lathe, Overhaul ‘92 Base REF#103 REF#102 OKOMATO Model #SHG-360H, 15” Diam, Yr ‘80’s REF#106 FELLOWS Model #12H, Lead checker, 12” Diam, 80mm Recording SKODA Model #SR90/3600, Centre Lathe, Yr ‘63 REF#102 PFAUTER Model #PE-1200G, 47” Diam, New ‘95 REF#106 System REF#103 TOS Model #SU125H/8000, Univ. Center Lathe, Yr ‘02 REF#102 REISHAUER Model #RZ-301S/AS, 13” Diam, Yr ‘90’s REF#106 FELLOWS Model #12M, Involute Checkers,12” Diam, Warranty TOS Hulin Model #SKIQ 8, CNC, Vertical Lathe, Yr ‘89 REF#102 RED RING Model #SF-500, 26” Diam, Yr ‘88 REF#106 REF#103 KOVOSVIT Model #VOM50, Radial Drilling Mach., Yr ‘89 REF#102 REISHAUER Model #RZ-300E, 12” Diam, Yr ‘86 REF#106 FELLOWS Model #4FPRL, Redliner, 4” Diam, Solid State Recording KOVOSVIT Model #VO-50/1250, Radial Drilling Mach., Yr ‘83 REF#102 REISHAUER Model #RZ-301S, 13” Diam, Yr’88 REF#106 REF#103 KOVOSVIT Model #VO-50/1600, Radial Drilling Mach., Yr ‘82 REF#102 REISHAUER Model #AZA/AZA-K, 11” Diam, Yr ’77-89 REF#106 FELLOWS Model #4FPRL, Redliner, Remanufactured, New KOVOSVIT Model #VO-50/1600, Radial Drilling Mach., Yr ‘84 REF#102 REISHAUER Model #ZB, 27.5” Diam, Yr ‘70 REF#106 w/Warranty REF#103 KOVOSVIT Model #VO-50/1600, Radial Drilling Mach., Yr ‘91 REF#102 MAAG Model #SD-62/82, 32” Swing, Wheel Dresser, Yr ‘82 REF#107 FELLOWS Model #20M, Redliner, 20” Diam, Very nice, Yr ‘69 REF#103 KOVOSVIT Model #VO-63/2000, Radial Drilling Mach., Yr ‘85 REF#102 GEAR RACK SHAPERS FELLOWS Model #20M, Redliner, Remanufactured, New w/Warranty REF#103 KOVOSVIT Model #VO-63/2000, Radial Drilling Mach., Yr ‘92 REF#102 FELLOWS Model #3X36, 36” Length, 3” Face, New ‘60 REF#106 FELLOWS Model #24M, Involute, Checker, 24” Diam, 80mm KOVOSVIT Model #VO-80, Radial Drilling Mach., Yr ‘87 REF#102 FELLOWS Model #61A, 48” Att, Reb ‘90’s REF#106 Recording REF#103 KOVOSVIT Model #VO-80, Radial Drilling Mach., Yr ‘90 REF#102 MIKRON Model #134, 1.1” Face, 14.4” Length REF#106 FELLOWS Model #24H, Lead checker, 24” Diam, 80mm Recording KOVOSVIT Model #VR84A, Radial Drilling Mach., Overhaul ‘00 SYKES Model #1800R, 72” Cut Length REF#106 REF#103 REF#102

gearsolutionsonline.com • JULY 2003 • GEAR SOLUTIONS 35 MARKETPLACE

Contact Gear Solutions at 800-366-2185 to feature your business in the Marketplace!

Quality Fine and Medium Allen Adams Shaper Services, Inc. Quality Fine and Medium Pitch Gears for Every Servicing Fellows Industry and Application Gear Shapers Up to 8” — Close Tolerances

On Site Service: Emergency & Scheduled Technical Support: Via Telephone. Fax or E-mail Bevel Worms Training: Operator, Set Up & Maintenance (Electrical & Mechanical) Pinions Worm Gears Preventive Maintenance plans: Customized to Your Needs Shafts Sprockets Parts: New and/or Used Spur Ratchets Retrofits – Counters, Servo Controllers, or Single and Multiple Axis CNC Helical Timing Pulleys Hydrostatic Guides: Repair Service or Purchase New

I am the former Service and Technical Support Manager Specializing in Medium Runs for Fellows. Working with me are several former Fellows Quality Assurance: ISO-9002 Certified Service Engineers. Between us we have the knowledge and capability to support all modes of Fellows shapers from the oldest to the newest CNC and Hydrostroke Phone: (800) 811-3416 machines. Please consider us for all of your Shaper needs. (815) 537-5111 Fax (815) 537-2871 Allen Adams www.americangearinc.com 910 Swanson Telephone: 802-259-2937 P.O. Box 156, Dept. AD Fax: 802-259-3937 Prophetstown, IL 61277 e-mail: [email protected] AMERICAN GEARS ARE EVERYWHERE!

DC MICRO GEAR MOTORS The Source for Quality DC Motors EXPERIENCE For over 25 years, Douglas International has been meeting customers’ requirements in the micro motor industry. Put our experience to work for you. Ultra-precision, 7—Type QUALITY Remanufactured. Gear Shapers Your application requiring high-efficiency, low electrical noise, and low mechanical Unmatched in dependability and • Hand scraped to certified noise can be consistently satisfied with Douglas International’s high quality motors. versatility for internal/external, masters for precise alignments SELECTION gears/splines and slots. • Hard chromed and ground Douglas International offers a wide selection of standard motors with power wear surfaces for extended life outputs ranging from milliwatts to hundreds of watts. Custom windings are • Anti friction coatings for available to meet your specifications. reduced clearances and GEAR reducers increased accuracy A wide range of gear reducers with rated output torques of up to 50 in-lbs is • Cutter spindle and bushing offered by Douglas International for use with our motors. burnished together for near zero clearance fit PERFORMANCE • All new bearings, IEC panel Douglas International can make the “motor fit the application” rather than asking and high efficiency drive motor you to make the “application fit the motor”. Call us today to determine how we can • Automotive quality, help you optimize your product’s performance. Polane finish douglas international, inc. GEAR WORKS, INC. • Factory apprenticed craftsmen 304 Paddock Road with the most experience 312 West State St., Geneva, IL 60134 Springfield, Vermont 05156 available anywhere PHONE: 630-232-7419 • Fax: 630-232-9394 Phone (802) 885-5039 • Best warranty in the business EmAIL: [email protected] Fax (802) 885-5176 www.douglasmotors.com Email [email protected] • Full line of popular parts www.vermontel.net/~gwi/ and accessories

36 GEAR SOLUTIONS • JULY 2003 • gearsolutionsonline.com REPRESENTATIVES WANTED ISLAND HIGHTORQUE ROTARY Machinery Service Premier Gear Tool Manufacturer seeking Fellows Gear Measuring Experienced Manufacturer Fellows Gear Measuring Representatives Instruments in key gear cutting territories GEARING & ENGINEERING Preventive Maintenance/ including Mexico & Canada Calibration Services/Repair Individuals or organizations interested in furnishing Custom Designed Planetary Retrofit/Parts/Supplies gear producers HOBS, SHAPER CUTTERS, MAAG OEM Approved CUTTERS, SHAVING CUTTERS & GEAR MILLING and Helical Gearboxes Instruments in Stock CUTTERS of the Highest Quality, manufactured Instruments in Stock by State-of-the-Art Facilities should contact: Island Machinery is a full JAN THOMAS at 440-331-0038, Fax 440-331-0516. Design Engineering Services service Equipment Dealer Specializing in gear testing [email protected] and inspection equipment. GREG ALLEN COMPANY HIGH TORQUE ROTARY Island Machinery Service SOLE NORTH AMERICAN DISTRIBUTOR FOR Phone: 715-463-3424 55 Widewater Road • Hilton Head, SC 29926 DRAGON CUTTING TOOLS 201 South Pine Street 843-681-9697 (Phone) • 843-342-2049 (Fax) TRANSMECANICA S.A.C.I. [email protected] Fax: 715-825-3151 P.O. Box 339 • Grantsburg, WI 54840 www.island-machinery.com

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gearsolutionsonline.com • JULY 2003 • GEAR SOLUTIONS 37 << from page 31 results specified by the customer. plating at this stage provides a more industry average of 10 to 12 weeks. Among the most important in achiev- uniform thickness and higher hardness “We’ve actually managed to reduce our ing uniformity of the abrasive layer is of the nickel plating. Simply put, if delivery from eight to 10 weeks on new Gleason’s proprietary electroplating you can’t control the layering of the wheels down to six weeks or less,” says chemistry. After a thorough ultrasonic nickel, you can’t control the tolerances Werner. “Nor are we limited to just gear cleaning to ensure that cores are free of the profile. Electroless is the only applications or new wheels. We’ve found of contaminants, the cores are put in way to gain this control.” a receptive audience in other industries, engineered precision masking fixtures The finished wheel is then put as well as for non-gear related applica- to protect non-plated surfaces. An through a rigorous inspection process tions. We are also an excellent source for electrolytic process then uses nickel that includes the microscopic evaluation the replating and refurbishment of all to tack down the abrasive to the to verify particle distribution, and the types and sizes of wheels.” exposed wheel profile. The duration full-profile grinding (on an actual CNC of this process and the required grinder) and inspection of a graphite amperage is precisely controlled coupon, thus verifying that the wheel based on the abrasive size and the will achieve the desired accuracies. surface area it covers. But it’s the next step in the process ABOUT THE AUTHOR: that’s really critical, according to More Leads, Less Lead Time Michael Hayes is president of Hayes Werner. “Once we’ve achieved this ini- Since the facility ramped up to full Marketing, which represents the tial bonding of a single layer of CBN production, Gleason Cutting Tools has Gleason Cutting Tool Corporation. to the wheel, it’s necessary to ‘tack seen the demand for its high-quality More information on Gleason’s down’ the layer and encapsulate the products rapidly increase—and its lead plating facility can be found on the crystals by building up the nickel to times decrease. Despite the fact that the company’s Web site [www.gleason.com] perhaps 50 to 60 percent of the height facility now produces the industry’s high- or can be obtained by calling of a crystal,” he says. “Most suppliers est-quality CBN and diamond plated (815) 877-8900. continue to use the electrolytic process, wheels, it has been able to reduce lead but we’ve proven that electroless nickel times for these products well below the

Parts for your INDUSTRIAL FELLOWS® Gear Machines CLUTCHES Model HC Clutch FELLOWS® The Model HC is an oil-immersed clutch designed for Specializing in 10-2, 10-4, 20-4, 20-8, 50-8, end-shaft, or through shaft mounting configuration. FS-180, FS-400, FS-630 The compact size of the HC makes these units ideal for incorporation within a gear housing. Multiple speed With over 25 years in the transmissions use a variety of these units to affect Gear Industry, I have fixed mesh speed changes. The Model HC may be used created an exclusive as a stand-alone device for disconnects service, network that can supply or conveyor/mill soft starts. both new and used parts. Obsolete parts can be done FEATURES INCLUDE: faster and less expensive • Pneumatic or hydraulic actuation than our competitors. • Clutch torque capacities range from Give us a call and 55,000 to 1,275,000 pound-inches find out for yourself!

Jim Kirkland P.O. Box 1019 • Elyria, OH 44036-1019 2800 Fisher Road • Wichita Falls, TX 76302 515 Frederick St. • Waukesha, WI 53187 216-389-5041 (cell) Office: 440-365-6045 • Fax: 440-365-6059 1-800-964-3262 866-547-3357 E-mail: [email protected] www.wichitaclutch.com www.indclutch.com [email protected] [email protected]

38 GEAR SOLUTIONS • JULY 2003 • gearsolutionsonline.com Index of MACHINE ENTERPRISES Advertisers INC.

COMPANY NAME PAGE

AG&I Cutting Tools 24 AGMA 16 Allen Adams Shaper Services, Inc. 36 American Gear, Inc. 36 Ash Gear 29 Bourn & Koch 28 YOUR SOURCE C-B Gear 17 #1 Carnes-Miller Gear 21 FOR NEW & USED Corrugated Replacements, Inc. 36 Douglas International, Inc. 36 GEAR MACHINERY eldec Induction USA, Inc. 12 R.P. Machine Enterprises Inc. is one of the largest stocking Encoder Products 36 gear dealers in the United States. We specialize in the buying Fassler Corp. 7 FHUSA 10 and selling of Gear Machinery. We sell Fellows, Lorenz, G&E, Gear Works, Inc. 36 Pfauter, Barber-Colman, Liebherr and other manufactured Gear Greg Allen Company IFC,37 Machinery. The majority of the machinery we advertise, we Havlik Gear 23 Havlik International Machinery, Inc. 2 own! Inspect machines under power in our 50,000 square foot High Performance Gear 22 facility. We repair our equipment on site. Let us quote your High Torque Rotary Engineering 37 Turn-Key operation. Our contacts are worldwide. We buy Hydra-Lock Corporation 9 entire plants and individual machines. Our inventory is updated Index Technologies 28 Island Machinery 37 weekly. Feel free to speak with us about any J. M. Kirkland Co. 38 machines you require or have for sale. We Jerry Tools, Inc. 37 offer MDNA one-year service warranty and Kreiter-Geartech 37 Lawler Gear Corp. 20 AGMA 10% off first machine purchase. LeCount, Inc. 1 Matthews Marking 37 We Offer CNC Control Retrofits mG miniGears North America 25 Midwest Gear & Tool Co. 20 Outsourcing Opportunities Mitsubishi Gear Technology Center BC Modern Gearing 29 Parts, Change Gears, Repair Service Mohawk Machinery 8 Moore Gear & Manufacturing Co. 31 325 N. Miller Ave. New England Gear 5 Statesville, NC 28677 • USA Nye Lubricants Inc. 37 704.872.8888 OEM Industries Inc. 37 Precision Gage Co. Inc. 12 fax 704.872.5777 R. P. Machine Enterprises, Inc. 32,39 [email protected] Rebco Industrial 31 visit our website @ Repair Parts, Inc. 30 www.rpmachine.com Russell, Holbrook & Henderson 11 St. Louis Gear Co. 30 Visit us at booth #101 at Gear Standard Steel Specialty Co. 37 Expo 2003 in Columbus, Ohio Wichita/Industrial Clutch 38

gearsolutionsonline.com • JULY 2003 • GEAR SOLUTIONS 39 Q&A Our Conversations with Industry Leaders

with Greg Allen Founder and President, Greg Allen Company

GS: I understand that you’re the sole U.S. dis- finest steel companies in the world. They had five tributor for Dragon Precision Tools. How did that Reishauer grinders and more on the way, which is come about? more than anybody else in the entire Pacific Rim. GA: My first exposure to Dragon was in 1989. I We’re now the sole distributor for Dragon in was working for a company called Cleveland Cutter Mexico, Canada, and the United States, in fact. and Reamer, and we were making hobs and shaper cutters. But there was a capacity issue in GS: It appears that you really did your homework the industry at that time, and we, as well as our before deciding to take them on. “I have a relationship with competitors, had a hard time fulfilling demand, so GA: I don’t want to just import tools, put my name I started combing the world to find other manufac- on them, and mark them up. The way I see it, every my customers and suppliers turers. Here we were in the United States, the hob, every shaper cutter that I sell has my name that’s based on trust. largest gear market in the world, yet we only had on it, literally, and that’s something that I don’t two or three primary suppliers, and I thought “you take lightly. So I’ve got to sell myself on the prod- So when I ask a company know, there has to be other companies that can uct first before I’ll sell it to anybody else. to try one of my tools, furnish quality tools.” I heard about a company called Dragon Cutting Tools back in 1988, and the GS: Apart from Dragon’s sophisticated manufac- they know they’re not president and founder, Mr. Chun, and I decided to turing facility, can you give me an example of some- meet. He didn’t speak English, and I didn’t speak thing that impressed you about their operation? going to be stuck with it Korean, so I invited my Korean dry cleaner to have GA: What impressed me the most is the way they go if it doesn’t perform.” lunch with us to facilitate the discussion. So that’s about making their hobs. Dragon uses a uniquely when the relationship was formed. configured form grinding wheel that can stay in the threads longer, which translates to greater precision “ GS: What happened between that time and 1996, and leaves less of a heel on the hob itself. It takes a when you officially formed the Greg Allen little longer to grind a hob, but it’s worth it, because Company? it adds so much service life to their product. Astute GA: The company I was working for was acquired end users recognize this feature right away. ” by Pfauter back in 1992, and I was regional sales manager with them for about four years. But I’d GS: I know that all of the manufacturers you rep- never let go of the idea of introducing U.S. gear resent are found outside the United States. Has producers to an international gear tool supplier that presented a challenge? base. I left Pfauter on good terms, and once my GA: I have a relationship with my customers and For more information, contact non-compete clause had run out, I contacted suppliers that’s based on trust. So when I ask a Dragon to get the ball rolling again. The following company to try a Dragon hob, or a shaper cutter Greg Allen Company at (440) September, Mr. Chun and I got together at the made by Transmecanica—which is based in IMTS show, and he had Young Jong Chun with him, Buenos Aires—they know they’re not going to be 331-0038 of visit their who handled international sales and spoke very stuck with it if it doesn’t perform. But these tools Web site, [www.gallenco.com]. good English. It was clear to me that Dragon was don’t break, they last longer, and they meet or sur- very keen on the U.S. market. pass our customer’s expectations.

GS: Sounds like that’s when the two of you really GS: Beyond Dragon and Transmecanica, do you started making some progress in your relationship. have plans to pull in any additional lines? GA: I’d seen his tools, of course, and I was GA: Absolutely. We are lucky to have Jan Thomas impressed by the quality, but I’d never visited their managing the office. She’s been in the business plant. While we were at the show, though, he since 1978, and she spent 10 years as U.S. sales showed me the list of equipment that he had in his manager for David Brown gear cutting tools out of factory, and what he had on paper was as strong the United Kingdom before she joined the compa- as any manufacturing capability you could find in ny about a year and a half ago. We also own an in- this country. So I went to Seoul about a month house gear tool sharpening division, Index later to visit his plant, and I was very impressed Technologies, Inc., which services everything that with what they had. You could’ve put that plant any- we sell. What makes it all worthwhile is when I where in this country and it would be a premier identify a quality tool and get it in the hands of my facility. And I was also impressed with their cus- customers and hear them say “man, these tools tomer base, which includes automakers like Kia, are really good!” When we accomplish that, I feel Hyundai, and Daewoo. They do their own heat like we’ve had a hand in helping our customers treating, and their raw materials come from the reach their goals.

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