Gear Resonance Analysis

GEAR SOLUTIONS MAGAZINE

GEAR RESONANCE ANALYSIS Using Rapid Prototyped Gears Upgrading and Testing a 72,000 HP GEARBOX INNOVATION IN Spline Rolling Rack Tooling UNIMILL: Prototype and Bevel Gear

IMTS 2014 Manufacturing SEPTEMBER 2014

Your Resource for Machines, Services, and Tooling for the Gear Industry SEPTEMBER 2014 gearsolutions.com Indiana Technology & Manufacturing Companies, Inc. (ITAMCO), left to right: Nobel Neidig - President Joel D. Neidig - Technology Manager Gary Neidig - Vice President

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Invest in your future. Kapp Niles machines provide increased productivity to grow your business. Our machines are built for the long haul, so you can pass them down from generation to generation – with 97% of our finishing machines still in operation since 1984. Plus, our quality service and retrofitting capabilities allow you to stay current with changing technologies. Invest in Kapp-Niles and invest in the future of your business.

ZPI/E: Profile grinding of internal gears with large modules. Switches from internal to external grinding by swiveling the grinding arm 1800. Wheels are dressed while in grinding position. Precise, efficient, flexible.

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GMTA Ad4992 GS June 2014 46 Features Upgrading and Testing a 72,000 H.P. Gearbox Company Profile: By Roland Ramberg Robust Gear Transmitting 54 megawatts, or 72,000 By Tim Byrd horsepower at a pitch-line velocity of Robust Gear has been 29,000 feet per minute is not child’s play. 28 manufacturing high-quality custom precision gears for over 25 years, and they aren’t slowing down.

Gear Resonance Analysis and Experimental Verification Using Rapid Prototyped Gears 32 By Scott R. Davidson and Jeffrey D. Hayes Tests to reduce risk are used to build confidence in the design and analysis techniques before the final product reaches an aircraft.

UNIMILL: Prototype By Hermann J. Stadtfeld The UNIMILL method produces bevel 56 gear geometries identical to those produced with face milling cutters.

A New Innovation in Spline Rolling Rack Tooling By Mike Callesen The R/C Rack System is the first major innovation in spline rack tooling 72 since the inception of the process 60 years ago.

SEPTEMBER 2014 3 Booth #N-7112

BroachmasterFP.indd 4 12/20/11 2:36:20 PM Resources MACHINERY Departments

82 Industry News MARKETPLACE Reports, data, and developments to keep you aware of what’s happening with your colleagues in the gear-manufacturing industry around the country and world. 8 85 Materials Matter ADVERTISER Fred Eberle INDEX DIN 5481 type spline serrations can be manufactured by milling cutter, hob, broach, and rolling. 22

87 Tooth Tips SEPTEMBER 2014 | VOLUME 12 / NO. 09 Ron Green The high cost of dry cutting is offset by the higher cutting speeds it offers. 24 Gear Solutions (ISSN 1933 - 7507) is published monthly by Media Solutions, Inc., 266D Yeager Parkway Pelham, AL 35124. Phone (205) 380-1573 Fax (205) 380-1580 International subscription rates: $72.00 per year. Periodicals Postage Paid Hot Seat at Pelham AL and at additional mailing Jack Titus offices. Printed in the USA. POSTMASTER: Metallurgical and heat treat forensics play an important part in determining why parts fail. 26 Send address changes to Gear Solutions magazine, P.O. Box 1210 Pelham AL 35124. Publications mail agreement No. 41395015 return undeliverable Canadian addresses to P.O. Box 503 RPO West Beaver Creek Richmond Hill, ON L4B4R6. Trend Talks Tim Byrd Copyright 2006 by Media Solutions, Inc. All rights reserved. Gear Solutions speaks with a handful of industry experts about how precision technology has shaped their products and clientele. 27

No part of this publication may be repro- duced or transmitted in any form or by any means, electronic or mechanical, including photocopy, recording, or any information Q&A storage-and-retrieval system without per- Bruce Cox mission in writing from the publisher. The Bruce Cox Engineering Corporation views expressed by those not on the staff 88 on Gear Solutions magazine, or who are not specifically 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 American cleared for release. Comments and submis- Gear Manufacturers sions are welcome, and can be submitted to [email protected]. Association 17

In this section, the premier supporter of gear manufacturing in the United States and beyond shares news of the organization’s activities, upcoming educational and training opportunities, technical meetings and seminars, standards development, and the actions of AGMA councils and committees.

SEPTEMBER 2014 5 LETTER FROM THEEDITOR David C. Cooper PUBLISHER When I mentioned this month’s Trend Talk to my publisher, “Precision Technology,” he laughed. “As compared to what, exactly? Imprecise technology?” Chad Morrison I had to admit, precision technology is a topic so broad it almost sounds like a marketing ASSOCIATE PUBLISHER buzzword (I’m looking at you, “synergy”). But the precision technology used to create a gear is so fascinating, so beyond my comprehension, that I had to focus on it. EDITORIAL It’s a self-evident truth that every finished gear has to be perfect — so that we can make even Stephen Sisk better ones. Better tools, designs, processes, and performance. Technological improvement EDITOR takes gear manufacturing to the next level, then it opens up a market for more improvement. These guys are always thinking like 20 years ahead. Tim Byrd But I’ve been wondering lately if there will ever come a fever pitch. I mean, how precise can MANAGING EDITOR you be? Down to these infinitesimal microns? At some point, won’t things just ... disappear? No, and here’s why: the tools are as precise as the gears they produce. You have to be precise SALES when making a gear, because they are used so much in so many applications and industries. Chad Morrison But precision is invaluable. When my publisher gets the editorial section from me, he expects ASSOCIATE PUBLISHER it to be right. Speaking of precision, industry, and the next level, this month’s Gear Solutions has all three in the form of articles from four American gear experts. The Boeing Company presented a CIRCULATION paper at last year’s FTM about gear resonance in aerospace applications, which we’re excited Teresa Cooper to present. Gleason’s UNIMILL has unlimited compatibility to the cutting and grinding with MANAGER face cutters. All existing design and optimization computer programs can be used — talk about precise! Kassie Boggan COORDINATOR One of my favorite parts of the Gear Works Seattle article “Updating and Testing a 72,000 HP Gearbox” is the subhead: “This isn’t going to be easy.” And, from the looks of the article, Jamie Willett it wasn’t easy. But the results were more than a little impressive. Six months after installing ASSISTANT and operating the upgraded gearbox, a thorough inspection of the rotating elements was conducted by Artec onboard the FPSO vessel. To everyone’s delight, the vibration and temperature ART records revealed no indication of problems and the gears looked beautiful, showing no signs of Jeremy Allen distress. Finally, the R/C Rack System promises to revolutionize the industry and will provide CREATIVE DIRECTOR U.S. Gear Tools access to the global spline rack market from its single manufacturing plant in the United States. Rebecca Allen When I write a grocery list, I’m don’t think about the pencil or the color of the paper. I’m GRAPHIC DESIGNER thinking about what I’m writing. The content of the document is what’s really important, not Michele Hall the tools I’m using to produce it. But if you don’t have the right tools — gear or pencil — then GRAPHIC DESIGNER you can’t complete the job. Suddenly, the tool you rely on is causing a serious problem with the finished product. Don’t make that mistake. Use Gear Solutions as a guide to the best help in the gear industry CONTRIBUTING WRITERS — download our app, visit www.gearsolutions.com, email me at [email protected], MIKE CALLESEN FRED EBERLE or just call me. SCOTT R. DAVIDSON RON GREEN Thanks for Reading! JEFFREY D. HAYES ROLAND RAMBERG HERMANN J. STADTFELD Sincerely, JACK TITUS Vertical Logo Horizontal Logo

Tim Byrd managing editor PUBLISHED BY MEDIA SOLUTIONS, INC. Coop wants to use this one for the website Gear Solutions magazine P. O. BOX 1987 • PELHAM, AL 35124 [email protected] (800) 366-2185 • (205) 380-1580 FAX (800) 366-2185 x205 David C. Cooper PRESIDENT

Chad Morrison VICE PRESIDENT

Teresa Cooper OPERATIONS 6 gearsolutions.com NEG_Ad final_03.14.pdf 1 4/11/14 10:19 AM

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is the most important investment for the future. With this philosophy, he started an apprenticeship workshop within his manufacturing facility in Coburg. Dr. Kapp’s expertise and leadership was also in demand by other companies. Numerous national and international companies and institutions have named him to their management and supervisory boards — the German Trade Fair and Exhibition AG, Gildemeister, Fiat, Krupp Hoesch, Iveco, Internazionale Holding Fiat, Werner & Pfleiderer, Trumpf, the Ifo Institute, the Fraunhofer Society, and the University of Coburg. Dr. Kapp’s ideals continue to flourish today, with the success of the Kapp Group under the leadership of his son, Martin Kapp. The machine tool and gear industries have lost a revered man, and true pioneer with the passing of Dr. Bernhard Kapp.

Brevini Gear Systems Hires New Director of Sales Chad Torn has joined Brevini Gear Systems Dr.-Ing E. H. Bernhard Kapp, company at the age of 29. He success- as director of sales. In this role, Torn will be German Machine Tool Industry fully led this company for 27 years with his responsible for developing the strategic sales Leader, Dies at 93 brother-in-law Otto Waldrich. channels and growing the business. Torn Dr. -Ing. E. H. Bernhard Kapp, a passion- In 1953 he founded his own company, brings a wealth of experience and a pas- ate entrepenuer and founder of the Kapp KAPP & CO in Coburg, motivated by sion for building relationships. The company Group, passed away on July 13, 2014 at the urge to create something of his own, believes he will be a great asset, and is excited the age of 93. His inventiveness and lead- and to generate jobs. Today, the KAPP to have him onboard. ership spanned 50 years in the machine Group is among the world’s leading manu- Brevini Gear Systems has also signed tool industry. facturers of machine tools for hard and an agreement with Water Wall Turbine Following five years in the military and soft finishing of gears and profiles with Inc. (WWTurbine) of Vancouver, British completing his studies, Dr. Kapp started 850 employees worldwide and facilities in Columbia to provide an integrated mechani- his professional life at the firm Waldrich in Germany, USA, Brazil, Japan, and China. cal driveline for WWTurbine’s innovative Coburg as a design engineer. He became Dr. Kapp firmly believed qualified edu- in-flow water current technology for self a shareholder and general manager of the cational support and technical training floating parts.

Companies wishing to submit materials for inclusion in Industry News should contact the Managing Editor Tim Byrd at [email protected]. Releases accompanied by color images will be given first consideration.

8 gearsolutions.com The WWTurbine vessel leverages patented technology in a tethered above water architec- ture to provide the following overall benefits compared to other tidal flow power generation concepts:

• Highly efficient power extraction • Improved accessibility for maintenance and construction • Minimal environmental impacts • Scalable technology for 500kW, 1MW, 2MW, 5MW per unit • Deep or shallow waters operation • Bi- or mono-directional (tidal or river currents) For more information on Brevini Gear Systems, go to breviniusa.com.

Take a Virtual Field Trip with Holding parts Sandvik at IMTS Developed by educators and manufactur- that make the ing industry experts, “Technology Applied” is a virtual field trip that connects academic world go around courses to development of important products. The interactive web broadcast, from IMTS September 8th-13th in Chicago, will show students why math and science matters, and how Precision & Repeatability the courses they take today can be applied in productive and rewarding future careers. for Demanding Applications This 30-minute virtual field trip runs in three different episodes on Wednesday, Thursday, and Friday during IMTS-week, offering diverse At Hydra-Lock, we continue to develop our aspects of the trade show experience to teach- workholding technologies, engineering ers and their classrooms. Students will get to explore some of the most groundbreaking and industry’s best chucks and arbors while fascinating areas of today’s — and tomorrow’s providing application support to meet — applied technology. Topics include 3-D the increasing demands of industries additive printing for aerospace manufacturing, like gear manufacturing. Among helicopter engineering, and race car technology. our many innovations are solid- and According to JoAnn Mitchell, senior project split- steel expanding sleeve designs, leader of Sandvik Coromant, “Students can and the Conform-A® technology – all experience how manufacturing plays a key role geared to ensure reliability and quality for in their everyday lives and see the possibilities it your I.D. and O.D. applications. can offer. People can have a career in manufacturing that literally makes a difference in how we live.” The broadcast is appropriate for students in grades 5-12, college, and tech school. The field trip is organized by Sandvik Coromant and supported by the AMT, Haas, Fanuc, DMG Mori Seiki, Okuma, Hurco, Doosan, Mastercam, Koma Precision and Gardner Media. Originators and developers For more information on Sandvik at IMTS of Hydraulic Chucking www.hydralock.com 2014, visit www.sandvik.com.

SEPTEMBER 2014 9 AMT’s Emerging Technology Center to Feature technologies, such as additive manufacturing, all integrated in a 3-D-Printed Electric Car at IMTS digital environment. AMT’s Emerging Technology Center (ETC) is on track to For a look at emerging technology in action, UPS, the global “wow” IMTS 2014 visitors. logistics provider to IMTS and AMT, will showcase the latest in “At IMTS 2004, we created the Emerging Technology Center logistics technology and how it supports manufacturing. to present manufacturing ‘technologies of the future’ from leading universities and government research labs,” said Peter Eelman, Manufacturing Day Events Expected to vice president — exhibitions and communications, AMT. “This Top 1,500 in 2014 feature returned IMTS to its roots as a forum where the latest More than 1,500 manufacturing events across the country are esti- technologies are first seen. This year is no exception, and we are mated to mark the third-annual Manufacturing Day taking place confident that this will be the most exciting ETC effort yet.” Friday, Oct. 3, according to event co-producers. Manufacturing The number one “wow” factor in the ETC is sure to be the Day is designed to introduce as many people as possible to the complete construction of a 3D-printed electric car by IMTS part- important role played by manufacturing both in local communi- ner Local Motors. Local Motors will build and deliver the first ties and for the nation. The 2013 celebration included 831 official direct digital manufactured vehicle at IMTS 2014. events. Manufacturing Day is a national event, executed at the Designed by the company’s global community, and built using local level, that supports hundreds of manufacturers across North the material science and advanced manufacturing techniques America as they host students, teachers, parents, job seekers, available at the Manufacturing Demonstration Facility (MDF) and other local community members at open houses designed to at Oak Ridge National Laboratory (ORNL), Local Motors will showcase modern manufacturing technology and careers. produce an electric vehicle purpose-built for the urban transpor- A wide range of activities will be held across the country — tation needs of Chicago. from open house tours of manufacturing plants and educational The team will start from scratch, employing direct digital man- programs at community and technical colleges, to professional ufacturing techniques and technology integration to make the conferences and job fairs. Many municipalities are planning parts and assemble the vehicle. This is a real-world demonstra- events across the entire week and numerous states have declared tion of achieving sustainable manufacturing by using emerging October as Manufacturing Month.

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10 gearsolutions.com A panel of co-producers comprised of the in a coordinated effort, what manufactur- ties to their manufacturing sector and demon- Fabricators & Manufacturers Association ing really is. strating the contribution that manufacturing International (FMA), the National “The co-producer organizations, our part- makes to the local economy, we can ensure a Association of Manufacturers (NAM), the ners, and sponsors are gratified to see the better future and way of life for our children Manufacturing Institute (MI), the National rapid growth of Manufacturing Day, which and grandchildren. Our future depends on Institute of Standards and Technology’s was held for the first time just two years ago our ability to strengthen and advance this (NIST) Hollings Manufacturing Extension with 240 events,” said Ed Youdell, president vital sector of the nation’s economy.” Partnership (MEP), and guest producer and CEO of the Fabricators & Manufacturers Manufacturing Day media partner Industrial Strength Marketing (ISM) pro- Association. “By introducing local communi- Science Channel will celebrate with a vide the centralized support necessary to coordinate this nationwide array of simul- taneous events. Seamless rolled Rings · 4”-144”OD CARBON • ALLOY • STAINLESS “Today’s manufacturing is about advanced technologies, state of the art facilities, and fast paced work environments,” said Jennifer McNelly, president of The Manufacturing Institute. “Manufacturing Day expands knowledge and improves public perception about manufacturing by giving manufacturers an opportunity to open their doors and show, STILL WAITING ON YOUR DELIVERY? At McInnes Rolled Rings, we take pride in the high level of speed and service provided to each of our customers, large or small. When you need it now, trust McInnes.

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24-hour marathon of its “How It’s Made” waterjet cutting. In addition, they provide Training on Day 1 and ProNest Power program from Oct. 2-3 preceded by an tutorials on powerful production tools User on Day 2. The Advanced Productivity advertising campaign that encourages its such as the integration of ProNest to an Training is presented by Jim Colt, an avid viewers to go out and see how it’s made in ERP/MRP system, the synchronization of fabricator and 35-year Hypertherm veteran their own communities. work order flow and plate inventory, and widely known for his expertise on all metal The sponsors invite additional manufactur- efficient material utilization. cutting topics. Colt will cover plasma, laser, ers and organizations supporting the manu- Hypertherm will offer two separate days waterjet, and oxyfuel cutting. In addition, he facturing industry to join the program. of training in both Atlanta and Houston will show attendees how to properly inspect To learn more about Manufacturing — Hypertherm’s Advanced Productivity their plasma consumables, and offer tips Day, visit www.mfgday.com.

Hypertherm Offering Free Workshops on Advanced Cutting Topics Hypertherm, a U.S.-based manufacturer of plasma, laser, and waterjet cutting systems, is adding three new cities — Tulsa, Atlanta, and Houston — to its 2014 live training tour on advanced cutting topics. The workshops, valued at $250, are offered at no charge to people who cut metal and other industrial materials. On September 16, Tulsa will see Hypertherm’s ProNest Power User, an eight-hour training ses- sion designed for programmers currently using ProNest, or anyone wanting a thorough look at the software’s capabilities. Hypertherm CAM software experts share advanced, process-specific programming techniques for plasma, laser, oxyfuel, and

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SEPTEMBER 2014 13 aimed at helping companies increase consum- of the best fabricators and steel service cen- Manufacturing Technology able life. Colt estimates operators regularly ters in North America. Dates for this set of Orders Rise in June replace half used consumables, needlessly cost- training workshops are September 17 and 18 June U.S. manufacturing technology ing their company money. Dan McLenithan, (Atlanta) and September 18 and 19 (Houston.) orders totaled $405.73 million, according a product and application engineer special- Interested individuals can register for one to AMT (Association for Manufacturing izing in both CNC and torch height controls, day of training or both at www.hypertherm. Technology). This total, as reported by joins Colt for this training, which is also com/LiveTraining. Though there is no cost to companies participating in the USMTO eight hours in length. He covers a number attend any of these workshops. Space is limited program, was up 12.6% from May, but of performance strategies employed by some to ensure a good presenter to participant ratio. down 2.1% when compared with the total of $414.26 million reported for June 2013. With a year-to-date total of $2,349.38 million, 2014 is down 2.7% compared with 2013. “Order gains in June were driven by two factors—the end of the quarter and continued strength in key customer industries, especially automotive, aerospace, medical, and energy,” said Douglas K. Woods, AMT president. “What really war- rants attention, however, is a rise in the average value of orders, as this suggests manufacturers are making investments in greater productivity as well as capacity. Our forecasts suggest continued moderate growth throughout the rest of the year and going into 2015.” In October 2013, the AMT began making an adjustment to the USMTO report. Due to a change in survey participants, the year over year comparison number for metal forming and fabricating is not an accurate reflection of the data. The data for the past 12 months takes this change into consideration. The new chart reflects a consistent year over year comparison of the data at the current par- ticipation level. Both Patrick McGibbon and AMT We only use Rotek® rings to President Douglas Woods are available manufacture our industry-leading bearings. for further comment on USMTO and its importance as a leading economic From rolled rings to fully customized machined rings, we offer indicator. a wide range of sizes that give you the design flexibility For more information, visit amtonline.org you need. In fact, whatever your production demands, Rotek is behind you every step of the way. For a quote, Meet the Next Generation of visit www.rotek-inc.com or call us at (800) 221-8043. Universal Robots at IMTS Visitors to Universal Robots’ booth E-4841 at IMTS 2014 get the opportunity to program a robot with safety features Rotek Exceptional Rings Lead to Exceptional Bearings that adjust to the context it operates within. Esben Østergaard, CTO of Universal

14 gearsolutions.com the Danish robot manufacturer’s collab- All the new features of the 3rd genera- ics. The product portfolio includes the UR5 orative robot arms. tion robots have been certified by TÜV and UR10 models that handle payloads of up “With the integration of the True (Technischer Überwachungs-Verein — a to 11.3 lbs. and 22.6 lbs. respectively. Absolute Encoder, our robot-arms can German organization that work to vali- The six-axis robot arms weigh as little as be integrated even more easily into other date the safety of products) and tested in 40 lbs. with reach capabilities of up to 51 machineries while startup also becomes accordance with EN ISO 13849:2008 PL d inches. Repeatability of +/- .004” allows much faster and simpler for all applica- and EN ISO 10218-1:2011, Clause 5.4.3. quick precision handling of even micro- tions,” says Østergaard. Universal Robots Universal Robots is a result scopically small parts. For more informa- Unlike most other industrial robots with of many years of intensive research in robot- tion, visit imts.com incremental encoders that work like absolute encoders, until the battery runs out, the encoders in the UR robots are not battery driven, therefore named “True Absolute Encoders” eliminating the need to frequently re-initialize the robot arms Leaders for Over since their position in space is known in Gear Workholding despite the robot not requiring battery power to achieve this function. 60 Years Though the robot arms UR5 and UR10 GEAR FIXTURES FOR are equipped with numerous new fea- Grinding | Hobbing tures, Universal Robots remains true to Shaping | Shaving its approach of user-friendly, lightweight ______robots. Fixtures | Arbors Chucks | Collets The visual appearance of the six-jointed UR5 and UR10 robot arms, with a payload of 5/10 kilograms respectively, remains unchanged. But inside of the robot arm itself, as well as in the controller, are more hidden surprises; sixteen additional digital • Design and Build Custom Tooling I/Os doubles the number of built-in I/ • Outstanding On Time Delivery Os which are easy to configure either as • Consultations and Installation digital signals or as safety signals. The control box has a revised design • Rush Order Capability and a rebuilt controller to further improve • Set Up Reduction Solutions the possibilities for connecting equipment • Attractive Pricing to the control boxes. “We are the only manufacturer of light- Drewco designs and weight robot arms with a long lasting builds European experience in a wide variety of industries. quality tooling and Our R&D department worked hard in combines it with order to integrate input and feedback short lead-times and from end users into our product develop- attractive prices. ment,” comments Enrico Krogh Iversen, Universal Robots CEO, on the latest Tooling gears from 1” to 1,700lbs. development from Denmark. Experts at Tooling Up “With our flexible robot-arms, we Familes of Part Sizes address a broad target group — whether USE it is (un-)loading of CNC machines in a ten-man firm or a gluing-process at an automotive manufacturer, everyone benefits from our robots. Because they perform Be a Hero In Your Own Company the dull or harmful jobs that needed to be 262-886-5050 | [email protected] | www.drewco.com done by humans before,” says Iversen.

SEPTEMBER 2014 15 Our Lean Selection cam reﬂ ects our own core values. Precision, reliability, high performance.

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The Lean Selection cam is an economical and flexible machine concept for grinding camshafts in any lot size. The wheel- head can be equipped with up to two high-capacity grinding spindles. The high precision, freely programmable swiveling Elliptical Polygonal B-axis manages rough and finish grinding or the grinding of cam profile cam profile bearings and cam lobes in a single clamping.

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Erwin Junker Machinery, Inc. Phone: +1 847 488 0406 2541 Technology Drive, #410 E-Mail: [email protected] Elgin, IL 60124, USA www.junker-usa.com American Jill Johnson AGMA Director, Gear Manufacturers Member Services Association www.agma.org

Having the right information about our industry has never been more important.

Each day gear manufacturers are in- new product cases, and forecast financials subscribe in editable Excel spreadsheets, volved in decisions of finance, supply and volumes. so that you can use the data as needed to chain, procurement, and strategic devel- Each quarter, the AGMA Gear Market create your own internal forecasts. In ad- opment. Decision-making is becoming Report also presents forecasts of strength dition to the quarterly data and economic increasingly complex with volatility of and weakness of 10 end-user industries. presentation, the subscription also in- global events, commodity price fluctua- It does not just provide the overall condi- cludes one seat at both the spring and fall tions, and technological advancement. tions, but presents forecasts of the volume AGMA Marketing & Forecasting Confer- How can you gage success of your of each sector’s gearing purchases. The ences. The annual fee for the subscription company today? Are you successful? Are ten end-user industries include: is $2,000. others finding orders that you may be The next AGMA Marketing & Forecast- missing? • material handling ing Conference is October 22-23, 2014 at Having the right information about our • industrial machinery gears the Crowne Plaza O’Hare in Rosemont, industry has never been more important. • construction machinery gears IL. This event is open to ALL AGMA AGMA makes available to members a • farm machinery gears members and attendees will receive the lat- quarterly updated forecast on the eco- • commercial & service machinery gears est quarterly Gear Market Report. nomics and market conditions of the in- • power transmission equipment gears Having the right information is impor- dustry through the Gear Market Report. • mining and oil & gas field equipment tant, but the AGMA Gear Market Report The Gear Market Report is a compre- gears is not a one-time future predictor. It is com- hensive look at the current marketplace, • ship & offshore platform gears piled by forecasts based on historical data produced by IHS Economics, providing • railroad equipment gears and current and anticipated conditions. information on the U.S. economic condi- • aerospace gears Conditions change, so updated forecasts tions, industry conditions for gears, gear are necessary for the most effective plan- market bookings, and gear market ship- This comprehensive look provides in- ning. Consider registering today for the ments — current data and forecasts for valuable intelligence for gear manufactur- Fall Marketing & Forecasting Conference the next two to three years. ers working across multiple sectors. to hear our economists’ perspective on the IHS economists provide our member The Gear Market Report is available latest numbers and indicators you should be companies with intelligence and tools to to all AGMA members. Quarterly up- watching as you make strategic decisions for help you target opportunities, formulate dates are sent directly to members who your gear manufacturing company.

SEPTEMBER 2014 17 STAY CONNECTED TO THE INDUSTRY WITH AGMA’S E-NEWSLETTERS Each Tuesday, AGMA sends out a compilation list of general news items that have direct relevancy to those in the gear and power transmission industries. Currently, this email is delivered to more than 6,500 people and is free for anyone to receive.

Member e-Newsletter Distributed on alternating Thurs- days, this is the premier communica- tion from AGMA. This e-Newsletter contains both comprehensive member news (direct links to press releases on member company websites) as well as news from the association on upcoming events, training, and new resources. Contact Mary Ellen Doran, AGMA director of electronic communications, at [email protected] for complete details or to sign up to receive either of these e-Newsletters.

AGMA IS INVITING INTERESTED EXPERTS TO PARTICIPATE IN A NEW PROJECT The AGMA Helical Gear Rating Committee has started a new project to update the Information Sheet AGMA 925-A03, “Effect of Lubrication on Gear Surface Distress.” Currently, AGMA 925 gives methods for calculating elastohydrodynamic lubrication (EHL) film thickness and predicting the probability of wear, and methods for calculating the contact temperature and predicting the probability of scuffing. As part of the revision project, the committee is planning to update these methods and wishes to develop a method for predicting the probability of micropitting. Once completed, the committee plans to offer the new document for adoption by ISO Working Group on micropitting (WG 15). To enhance its current broad acceptance within the industry, the committee aims to make the revision project a multi-disciplinary effort that includes people from the gear industry, lubrication industry, academic and industrial researchers in tribology, and anyone interested in the tribology of gear teeth. If you are interested in taking part in this project, please contact Amir Aboutaleb, vice president of AGMA Technical Division. For more information about this event, and to register, visit AGMA online at www.agma.org.

18 gearsolutions.com CALENDAR OF EVENTS Whether you’re looking for technical education, networking opportunities, or a way for your voice to be heard in the standards process, AGMA has something to offer you. If you would like more information on any of the following events visit www.agma.org or send email to [email protected].

**Event open to AGMA members only. Not a member? Send e-mail to [email protected]. Gear Failure Analysis Seminar (SOLD OUT) – September 8-10, 2014 Big Sky, MT Lubrication Committee Meeting – September 9, 2014 WebEx Fine Pitch Gearing Committee Meeting – September 10, 2014 WebEx Mill Gearing Committee Meeting – September 12, 2014 WebEx Helical Gear Rating Committee Meeting – September 16-17, 2014 Chicago, IL Cutting Tools Committee Meeting – September 17, 2014 WebEx Wormgearing Committee Meeting – September 18, 2014 WebEx Enclosed Drives for Industrial Applications Committee Meeting – September 18, 2014 WebEx Metallurgy & Materials Committee Meeting – September 19, 2014 WebEx Basic Training for Gear Manufacturing (SOLD OUT) – September 22-26, 2014 Chicago, IL SEPTEMBER SRN Regional Event: Chicago Area – September 23-25, 2014 Chicago, IL Bevel Gearing Committee Meeting – September 23, 2014 WebEx Epicyclic Enclosed Drives Committee Meeting – September 25, 2014 WebEx Lubrication Committee Meeting – September 25, 2014 WebEx Gear Accuracy Committee Meeting – September 30, 2014 WebEx

Mill Gearing Committee Meeting – October 8, 2014 WebEx Metallurgy & Materials – October 8-9, 2014 Arlington, VA Plastics Gearing Committee Meeting – October 9-10, 2014 Arlington, VA Fall Technical Meeting – October 12-14, 2014 Arlington, VA Wind Turbine Committee Meeting – October 15-16, 2014 Arlington, VA Flexible Couplings Committee Meeting – October 15-16, 2014 Arlington, VA Bevel Gear System Design – October 15-17, 2014 Arlington, VA

OCTOBER Wormgearing Committee Meeting – October 21, 2014 WebEx Fall Marketing & Forecasting Conference – October 22-23, 2014 Rosemont, IL Mill Gearing Committee Meeting – October 23, 2014 WebEx Aerospace Gearing Committee Meeting – October 27-28, 2014 Portland, ME Powder Metallurgy Gearing Committee Meeting – October 30, 2014 2014 WebEx

Detailed Gear Design – November 5-7, 2014 Las Vegas, NV Wind Turbine Committee Meeting – November 6, 2014 WebEx Mill Gearing Committee Meeting – November 12, 2014 WebEx Wind Turbine Committee Meeting – November 13, 2014 WebEx Vehicle Gearing Committee Meeting – November 17, 2014 WebEx

NOVEMBER Plastics Committee Meeting – November 18, 2014 WebEx Cutting Tools Committee Meeting – November 19, 2014 WebEx Vehicle Gearing Committee Meeting – November 17, 2014 WebEx

SEPTEMBER 2014 19 DETAILED GEAR DESIGN • Use computer generated graphics to examine mesh action and tooth NOVEMBER 5-7, 2014 interaction HYATT PLACE • Gain new insight into the concepts presented through illustrations LAS VEGAS, NV and demonstrations • Use this classroom setting to put tried-and-true theories into prac- “Detailed Gear Design,” presented by Ray Drago for advanced stu- tice dents with a good understanding of basic gear theory and nomencla- • Interact with a group of your peers and with a talented and well- ture, covers all the factors going into good design from life cycle, load respected instructor who will push your thinking beyond its normal torque, and evaluating consequences. boundaries By attending this course, students will be able to: Computer generated animated graphics will be used for exam- • Improve gear designs ining mesh action and tooth interaction. Each section discussion • Better understand gear rating theory and analysis methods will be followed by a brief question and answer period. The reg- • Investigate differences in stress states among various surface dura- istration fee will include all meeting materials, scheduled meal bility failure modes functions, and an opening evening networking reception. A cer- • Discuss time dependent and time independent failure modes related tificate will be awarded to each attendee upon completion of the to tooth design seminar.

American 1001 N. Fairfax Street | Suite 500 Alexandria, VA 22314 Gear Manufacturers (703) 684-0211 | www.agma.org Association

AGMA LEADERSHIP

Lou Ertel: Chairman John Cross: President, ASI Technologies President & CEO, Overton Chicago Gear Corporation Kenneth J. Flowers: Owner and Vice President, Machine Tool Builders, Inc. Matt Mondek: Chairman Emeritus Bill Gornicki: Vice President Sales & Marketing, ALD Holcroft Vacuum Technologies Co., Inc. President/CEO, Reliance Gear Corporation John E. Grazia: President, GearTec Inc. Dean Burrows: Treasurer President,Nixon Gear Sulaiman Jamal: Managing Director, Bevel Gears India

John Strickland, Jr.: Chairman, BMEC Steve Janke: President, Brelie Gear Company, Inc. Fairfield Manufacturing Co. Jan Klingelnberg: CEO/CFO, Klingelnberg Buzz Maiuri: Chairman, TDEC EXECUTIVE COMMITTEE Senior Product Manager, The Gleason Works Justin McCarthy: Vice President , Sales, Scot Forge Company

Mark Michaud: President, REM Surface Engineering

BOARD OF DIRECTORS Brian L. Schultz: President, Great Lakes Industry, Inc. Joe T. Franklin, Jr.: President Dylan Smith: President, VanGear Amir Aboutaleb: Vice President , Technical Division

STAFF Wendy Young: President, Forest City Gear Company Jill Johnson: Director, Member Services

General requests: [email protected] | Membership questions: [email protected] | Gear Expo information: [email protected] Technical/Standards information: [email protected] | AGMA Foundation: [email protected]

20 gearsolutions.com We push the boundaries of technology to bring energy to the world.

Brought together in 2014 as part of the GE Oil & Gas family, Lufkin and Allen Gears—gearing powerhouses with long legacies of quality and reliability—deliver highly-engineered gearing products and services that enable our customers to reliably and safely bring energy to the world. Contact Allen Gears (http//www.allengears.com) and Lufkin (http//www.lufkin.com) today. Visit Lufkin and Allen Gears at the 43rd Turbomachinery Symposium in Booth #1019.

Part of GE Oil & Gas Part of GE Oil & Gas

geoilandgas/lufkin.com MATERIALS MATTER Fred Eberle Hi-Lex Automotive Center

DIN 5481 type spline serrations can be manufactured by milling cutter, hob, broach, and rolling.

THIS MONTH, WE WILL FOCUS ON CALCULATING AND SIZING DIN 5481 type spline serrations for any application. The latest document is a 2009 update to the original 1956 standard. However, the document is not available in the U.S. due to publishing restrictions. As far as I know, it is only printed in German. Figure 1: Spline Space Width at Contact Points Nevertheless, the procedure for designing with these straight-sided serrations is straightforward. The splines themselves make for connections that are simple, RELATIONS: elegant, easily calculated, and strong. They can be manufactured by milling cut- • Sin (/2) = h/rpin, ter, hob, broach, and rolling. Net shape molding is easily done with tooling readily • h = rpin*Sin(/2) made by many suppliers. • Cos(/2) = (L/2) / rpin = L / Dpin The DIN standard fixes spline serrations both internal and external with a • L = Dpin*Cos(/2) constant space angle of 60° for numbers of teeth between, 28 to 42 and pitch • H/2 = [MOW/2 - rpin – h] diameters from 7.0 mm up to 60.0 mm. For larger splines,, a constant space angle of 55° is specified for numbers of teeth between, 41 to 81 and pitch diameters of The key to serration tolerances: Space width 60.0 to 120.0 mm. clearance per side as shown is equal to: DIN 5481 includes standard tables for internal and external spline fits. This design data is tried and true. However, the document is in German and equations • Minimum, [0.5*(Min Internal MBW/2 - Max for the table data are not provided. For net shape gearing, this type of serration External MOW/2)] can be applied to any custom application requirements. Unique spline sizes and • Maximum, [0.5*(Max Internal MBW/2 - Min fits that are not found in the tabled data can be developed just by using the same External MOW/2)] geometric logic. Custom sizes are easily calculated by understanding the underly- ing basic geometry. Clearance fits between major and minor diameters are set by the designer by specifying internal/ The spline geometry, illustrated in Figure 1, is as follows: external diameters and root radii (see Figure 2). The choice of the inclusive angle is arbitrary but the DIN standard uses only Some examples of useful serations are as follows: 60° and 55° For ease of assembly, a net shape molded tapered spline, as illustrated in Figure 3, can be DEFINITIONS: designed. These are more complicated to execute • (L) = chord subtended by tangent points intersecting the pin diameter and the and measure, but they are developed exactly the serration space width same way as single straight splines. Pick two loca- • (MOW) = measure over wires, pins or balls for external Splines tions along the spline length, determine the taper • (MBW) = measure between wires, pins or balls for internal Splines (not shown) angle desired, and then determine the measure • (rpin) = radius of the pin, over wires or pins to suit your taper. Design of • (Dpin) = pin diameter • (h) = distance from the chord to the pin center • (H/2) = distance from center of spline axis to chord

ABOUT THE AUTHOR: Fred Eberle is a technical specialist in the development of gearing, drive motors, and power closure devices in the automotive industry. He currently serves on the AGMA Plastic and PM Gearing Committees. Eberle has authored several papers on gearing, measurement system analysis and process statistics. He can be reached at [email protected]. Figure 2: Mating Spline clearances.

22 gearsolutions.com the analysis. The strength will be determined by the number of teeth and portions of teeth in contact (see Figure 5). The load sharing is predicated on the physical tooth alignments. Plastics tend to deliver surprisingly good results especially in unfilled materials. The compliance of the teeth may result in complete load sharing, whereas in hardened steel splines compliant load sharing can be significantly limited. In these cases, the precision of the analysis will be predicated on accuracy of the components and assembly alignments in addition to experience and good engineer- Figure 3: Example of a tapered Spline. ing judgment regarding loaded tooth contacts within the application. The key to load sharing is deflection. FEA will give a theoretical result. But if axis alignments, pitch and lead varia- tions can be discerned and modeled, virtual contact can be evaluated to derate the theoretical result accordingly and lead to a more accurate analysis.

INSPECTION MEASUREMENTS OF INTERNAL SPLINES A drawback to measuring internal splines is

Figure 4: Example Int/Ext Spline connection. verifying the between-pin distance. This can be especially difficult when the component is the internal member is done by off-setting 4) of the same amount or one-half the amount non-metallic. As long as the pins are firmly the external member (via an increase in the per side when assembled. For example: if the held in place without causing deflection of distance between pins), then rotating it one center to the external pin is 10 mm and the the teeth, a particular concern with plastics, tooth space. Once done, the model is ready for center to the internal pin is 11 mm; then the a CMM can take measurements between the virtual assembly. total clearance will be 1 mm or 0.5 mm on the exposed wires. A cylindrical wedge can be side of each spline. This can be readily verified helpful to hold the pins in place, as illustrated AN IMPORTANT OBSERVATION by modeling. in Figure 6. However, with smaller modules The difference between the measure to the Determining the strength of the spline even this technique becomes more difficult. center of the (external) pin and the measure connections is reasonably easy with finite ele- In these cases and for high volume compo- to the center of the (internal) pin will result ment programs. The geometry is symmetrical. nents GO / NOGO gages are recommend- in a total space clearance between two mating Therefore, a small portion of the component ed. For modules of 0.7 and smaller, the splines (an example of which is seen in Figure and number of the teeth are only needed for gage may be the only reasonable choice.

Figure 5: Example of a Int Spline with an Ext spline Figure 6: Measurement of an Internal non-metallic Figure 7: Example of Spline drawing data for over-molding into a plastic connection. Spline.

SEPTEMBER 2014 23 Carbide hobs have shown that they can cut at very TOOTHTIPS high speeds, commonly 3 times faster than HSS and in dry conditions. The problem with these tools is the very ronGREEN high cost and the lack of strength in the sense of tooth Eaton Corporation breakage. They need to be handled with extreme care. Bridge materials bridge the gap between the abilities of traditional HSS and carbide materials. These materi- The high cost of dry cutting is offset by the higher als are capable of cutting without coolant and at higher speeds than HSS but not as high as carbide, perhaps cutting speeds it offers. 1.5 to 1.8 times as fast as HSS. A currently used bridge material from Crucible steel is CPM 121 (also called Rex 121). Their performance depends on the proper applica- TOOL COATINGS AND DRY CUTTING tion of various coatings. There has been a movement in recent years to dispense with the use of coolants in gear cutting. This has been normal practice in cutting cast iron but has been unachievable in the cutting of steel with “traditional” high speed steels. “Latest advances in

The advantages of dry cutting include: bridge materials and

• coolant cost coatings may supplant • cleaner environment • no coolant system on the machine carbides as they are • no disposal fees more forgiving in their The disadvantages include: application and still are

• higher cutting tool temperature able to run dry. These • no means to flush chips • very expensive cutting tools could also be called • tools are very brittle Super High Speed Steels.”

DP Range Practicality The standard coating for many years has been TiN, Titanium Nitride, and this remains a good starting point Finer than 28dp Certain for any cutting technology development. TiCN, Titanium Carbo-Nitride, was a later develop- 28-18 Dp Very good in most cases ment aimed at those areas where TiN was least effective, mainly abrasive and hard ( 300 BHN +) materials. 16- 12 DP Good with development Since then the technology of this coating has been developed to a point where it is now widely used as an 10-6 DP Possible improved coating. However, newer coatings will eventu- ally surpass TiCN. Coarser than 6 dp Not advisable TiAlN, titanium aluminum nitride, can also be used with coolant but is also the coating of choice for dry Figure 1 operations. In addition, there are several multi-layered coatings and multi-material coatings, most of a propri- ABOUT THE AUTHOR: etary nature. The state-of-the art with coatings in combination with “bridge” materials is rapidly changing, Ron Green is retired from Eaton Corporation as a chief engineer. He has over 60 years of experience in the gear industry. and any process change envisaged with these materials For more information, call (904) 392-0907. should be done in collaboration with a reputable supplier with experience in this application. 24 gearsolutions.com Recent developments include “super lat- erating roughing tools and inserted hobs are stronger than traditional carbides but tice” coatings containing titanium, alumi- which are capable of producing a profile still much more brittle than any type of num, chromium, ytrium, and nitrogen in close to finish requirements, close enough HSS. combination and a self lubricating coating of for subsequent finish grinding. In sum- The newer bridge materials have greater alternate layers of TiAlN with molybdenum mary the current state of the art in respect strength than carbide but less than HSS. disulfide (MoS2). to dry cutting is as follows: The bridge materials cut faster than “nor- The high cost is offset by the higher cut- mal” grades of HSS, but not as fast as CARBIDES ting speed. The latest micro fine carbides carbide. As stated, carbide is extremely brittle due to its very high hardness and tools made of this material break very easily. Again the complex shape of tools like hobs is a problem for such materials. On the other hand, carbide is capable of Complete Gear Manufacturing cutting at rates three times as fast as high speed steel and without coolant. Because of this there is a great deal of interest in its use and it is gradually finding its way into the high production areas of hobbing. Latest advances in bridge materials and coatings may supplant carbides as they are more forgiving in their application and still are able to run dry. These could also be called Super High Speed Steels as they are similar in composition and technology to regular HSS but with very high amounts of alloying materials such as cobalt and vanadium. There is also a consideration of tooth size in application of carbide and bridge materials. The coarser the pitch, the more difficult the application and the chance of a successful usage. We can say with some confidence that the following is true when cutting good machineable materials in the • Serving the Gear Industry for “normal” hardness ranges of 180 to 240 Over 20 Years BHN (Figure 1). The above comments re “carbide’s lack • Gear Grinding Services Featuring of strength” apply mainly to complex Newer CNC Gear Grinders shaped tools, especially hobs. Most machining (milling and turning) is today performed • Calibrated Analytical Gear Inspection with inserted blade cutters where simple Equipment regularly shaped, carbide bits are mechani- • Up to 200 Piece Lot Sizes cally locked into the tool body. Because of their shape, size and support from the tool • ISO 9001:2008 body, these are able to stand high cutting loads without breakage. In the event of a breakage the tool insert is easily and eco- 6125 11TH STREET • ROCKFORD, IL 61109 nomically replaced. PHONE: 815-874-3948 • FAX: 815-874-3817 This technology has entered the gear- www.raycargear.com cutting field with single index non-gen- SEPTEMBER 2014 25 commuter flights, as the airplane takes off and lands many times over a month. Obviously, designers take an HOTSEAT airplane’s intended purpose into consideration. Heat treat furnaces, like any complex machine, will, jackTITUS at times, suffer the same fate. Components fail. But Director of Process and Developmental every engineer must know the intended purpose and Engineering, AFC-Holcroft anticipate how the system will be used and how likely the user will follow the maintenance protocol. No matter if it’s for a household blender, furnace, automobile Metallurgical and heat treat forensics play an or airplane. Airplanes (for obvious reasons) must be important part in determining how and why parts fail. subjected to rigorous scheduled maintenance in order to catch potential failures before they can happen. Where heat treat furnaces are concerned, very AUTOMOBILES AND AIRPLANES HAVE BEEN in the news recently — GM cars high temperatures and explosive atmospheres are the for ignition recall issues and airplanes because of crashes due to weather, mis- critical parameters we must contend with and the heat siles, and undetermined reasons. No matter the case, metallurgical and heat resisting alloys we use in their construction. Just as car treat forensics play an important role in determining what and how things and airplane manufacturers have to retain records happen. from their supply chain, furnace providers do as well, Cars and airplanes contain steel, cast and wrought aluminum, copper, tita- to ensure that the systems comply with industrial risk nium, and composites, among other complex alloys of these same materials. insurers and our own quality system. Record retention It’s critical that the aftermath of any incident be preserved exactly as found so is intrinsic with today’s technology and off-site backup experts can piece together the clues that will always be present to help explain tape security. what occurred. Components can fail from fatigue, as described Let's consider, for example, an ordinary steel clothes hanger in these three above; workmanship, like misassembly causing unin- scenarios: tended wear; or improper heat treatment. This is what 1. Flex it back and forth repeatedly and the flex point will get warm (even investigators face when they reconstruct the situation hot) and get progressively harder to bend before it breaks. This is called work to find the root cause. One of the biggest puzzles to hardening, where the metal can actually become brittle where initially it could overcome in any failure investigation is heat and the be bent easily. length of time between the failure event and evidence 2. If the hanger is flexed more slowly over a time, instead of work hard- discovery. Heat can alter the microstructure of metal ening, the hanger will break from fatigue. It will break even when the force and oxidation from exposure or both. required to bend the hanger is well under the forced required to cause work So what occurred first? Did heat contribute to hardening. the failure by weakening a component or did heat 3. However, if the hanger were to be used to lift something heavy beyond alter the material after the fact? Sometimes this can its strength limit, instead of a chain, it will begin to neck down, at some point be determined by comparing the fracture surface reaching its yield strength, stretch, and then break. Now duplicate the three morphology to the quantity and type of oxidation tests at -70°F (-57°C), the temperature at an altitude of 35,000 feet and the on the part and knowing the intended heat treat- fracture surfaces of the hanger would be different to the experienced observer ment process. The time required to achieve the in an SEM (scanning electron microscope). It doesn’t matter how large or intended microstructure and the time the part actu- small the hanger is, the failure mode would be observable. ally received from records kept by the original heat I don't know why the failure mechanism caused the ignition switch failures. treater and hopefully a sample taken from the same But certainly a very small piece of metal or plastic moved from its intended processed lot. The metal in question is also an issue; position, either from vibration or excessive force from too much weight on the aluminum melts at 1000°F to 1100°F, but steel’s key fob, as mentioned in news stories. But since the failures didn’t occur very microstructure changes above 1333°F. soon after the cars were first placed in service, the failure mode was likely Another puzzle investigators must consider is related to fatigue of some component. mechanical deformation. Did the metal or compo- The classic failure mode related to airplanes is fatigue, either in the fuselage nent change shape as a result of the failure, or, in the around rivets or on wing surfaces when subjected to strong winds — especially case of an automobile or airplane, an impact with up and down drafts. The force created when landing is also an issue specifically for another object? Heat treaters are not immune from component failures, but rarely do they cause catastrophic dam- ABOUT THE AUTHOR: age. When they involve a car, airplane, or furnace Jack Titus can be reached at (248) 668-4040 or [email protected]. they are likely the result of improper human inter- Go online to www.afc-holcroft.com or www.ald-holcroft.com. vention somewhere along the human/machine inter- face process. 26 gearsolutions.com WITH DAZZLINGLY PRECISE MULTI-AXIS MACHINES, better technology is leading to better tools, design ideas, and better gears. It’s no surprise: metallur- TREND gists have been thinking 20 years ahead since, well, forever. When they invent something that takes gear manufacturing to the next level, it opens up a mar- TALKS ket for more improvement. timBYRD But I’ve been wondering lately if there will ever Gear Solutions come a fever pitch. I mean, how precise can you be? Down to these ridiculously small measurements, Gear Solutions speaks with a handful of industry microns? At some point, it’s just crazy. experts about how precision technology has Gears are the same thing. But the technology used to make a gear is way more complicated than shaped their products and clientele. to make a pencil. I spoke to three of the manufacturing experts I could find about how precision RANDY PEARSON technology has revolutioned, well, everything. SIEMENS “In gear production, operators need to tilt rotary tables around to get to the dif- NITIN CHAPHALKAR ferent teeth. With our product line, there’s a quick-set function used to calibrate a DMG Mori rotary table or calibrate the five axes on a machine so it knows where all the pivot “Gears have complex features to machine. points are. It previously took hours and hours, maybe even a couple days of work, Previously, many of the original methods of making to do all the calibration and measurements. It’s now in the hour-range. Users can gears took that complexity and put it into the tool perform their own calibration and check it monthly, quarterly, bi-weekly, so they design. So all the precision was in the tool. As the can calibrate very quickly.” tool wore out, the quality of the gear deteriorated. In the past, the machine would be out of commission for a day or two, and In precision technology, with complex objects the manufacturer would end up having to do it during a plant shutdown once or converted into complex tool parts, five axis machine twice a year. Now they can do it on a Friday and it’s ready on a Monday morning. motion became important. That’s where quality The more things can get done quickly, the more things people want to do to machine tools and cutting tools come in. The cut- maintain the precision of the machines. Mechanically, there’s still a lot to be done: ting tools are typically ground to a specific diameter preventative maintenance, condition monitoring, power consumption, being as with very minor tolerances. At the same time, we green as possible. But with these monitoring functions, it’s easier to maintain and have measurement techniques on the machine tools predict maintenance points that need to be addressed. like laser-based measurements. You predict, to the micron, the diameter of the tool. The machine SCOTT KNOY tools have significantly improved the resolution of GMTA the machine. Most of DMG Mori’s machine have “The high precision cnc machines have made it possible for manufacturers to 5 micron positioning accuracy. So by combining achieve much higher quality levels. As we see in the gearing world, a gear is only the correct tool measurement techniques and the as good as all of the processes that it takes to manufacture the gear. That trans- positioning accuracy and the volumetric accuracy, lates into better process control starting with your blanking process which provides which is important on a 5-axis machine, we can a higher quality blank to Scud or hob and the benefits just continue to pile up as make pretty accurate gears that are replicable.” you march down the production line. The result of high quality equipment, other than high quality parts, is cost reduction! If the machinery is not having to work Important things in precision gear technology: as hard as it once did in manufacturing/correcting the parts you will automati- 1. Getting the surface of the gear (with modifica- cally achieve better cycle times, which increases your throughput and capacities as tions) correctly modeled. well as increasing tool life. This all adds up to increased savings. Our interpolator 2. Preparing a toolpath based on the surface model. is a NURBS interpolator. We do everything internally as a spline.” 3. Measuring the tool dimensions correctly. As most parts are done as a point-point program, essentially every part that 4. Executing it to the highest accuracy possible. comes off a machine is a faceted part. Siemens technology takes all those points It will improve the overall quality of the gear. and runs a curve through the points to minimize the stops, making a smoother That is a common thread in how precision and transition from point to point. We’re using a velocity profile, as opposed to a machine tools are dedicated to the quality of the geometry profile. It reads ahead for getting the correct speeds for reversal and gear that can be machined. stopping, as opposed to relying on geometry.

Five axis technology has been being developed FOR MORE INFORMATION: for a long time. We have perfected it while applying Contact Tim Byrd, managing editor, Gear Solutions it to machine aerospace parts such as blades. We (205) 380-1573 ext. 205. are now applying it to the gear machining.

SEPTEMBER 2014 27

COMPANY PROFILE Robust Gear

Robust Gear has been manufacturing high quality custom precision gears for over 25 years, and they aren’t slowing down anytime soon.

By Tim Byrd

28 gearsolutions.com

ROBUST GEAR WAS INCORPORATED IN AUGUST 1985, BY TARSEM (SEM) TAK IN THE TOWN OF OAKVILLE, ONTARIO. TARSEM‘S DREAM WAS TO CREATE A NICHE IN THE CUSTOM GEAR MARKET THAT WOULD BE FULFILLED AND SERVICED BY HIS COMPANY.

By the time of his death in December 2012, Tarsem had Like his father, Anjan worked in all areas of the business, built up a solid reputation of honesty and lived by the com- beginning his career as the plant custodian. Anjan company motto he had established – “Quality gearing at qual- pleted his bachelor’s degree in honours economics with a ity prices”. minor in business from McMaster University in Hamilton, “My father was a certified millwright by trade, educated Ontario. Anjan has emulated his father’s work ethic and and trained in England,” states Sem’s son, Anjan. “He ap- integrity, along with Sem’s dedication and commitment to prenticed with the Aero-engine Division of Rolls Royce recognizing and meeting customer and employee needs. in the Midlands plant which was renowned for its impres- Today, the company has grown to include customers in Rsive rotational apprenticeship program.” It was at Rolls a host of industries, including aerospace, mining, OEM in- Royce that Sem developed a passion for solving complex dustrial equipment, pharmaceutical, packaging and more. machining and gearing problems. The technical experi- Robust Gear has recently expanded into the oil and gas ence he acquired at Rolls Royce became an integral part of market, providing gears for a variety of pipeline-related Sem’s knowledge base and approach to the manufacturing equipment. This industry now contributes about 15 per- and has been the key factor in the success of Robust Gear. cent to total revenues. Robust Gear also has the capability Being a self-starter, Sem was able to undertake jobs that of providing reverse engineering services for customers. required detailed processes and execute them with confi- When customers need to reproduce gears for which there dence. are no specifications on hand, Robust Gear is able to pro- Sem came to Canada in 1974, landing in Montreal, vide assistance in creating proto-types as well as drawings. Quebec where he was employed at a custom gear manu- According to Anjan, Robust Gear has been able to reman- facturer. He relocated to Oakville with the goal of using ufacture gears used in equipment ranging from cars to his expertise to open a gear manufacturing facility. After tractors to toy helicopters, not to mention complex clocks. months of research and deliberation, Sem founded Robust The company moved to their current facility in 2010 – Gear. a spacious 10,000 square-foot building complete with of- When he started the business in 1985, the shop was a fice space and an inspection room. With the help of plant mere 400 square-foot unit, per Anjan. In 1989, Sem ex- manager, Stewart Lord, Anjan has been instrumental in panded to a larger unit of 1,600 square feet. As equipment adopting and implementing lean principles of manufactur- purchases deemed necessary, plant expansion was the nat- ing. With the cooperation and commitment of its team of ural progression. The following year, Robust Gear leased employees, the company hopes to see further improvement an additional unit, taking the plant to 3,000 square feet. In in quality, visual management, efficiency, problem elimi- 2004, a 3rd unit became a necessity, with the purchase of a nation, a safer work environment and increased employee CNC Milling Centre. Total manufacturing space now ex- job satisfaction. Anjan believes adopting the lean manu- ceeded 4,500 square feet. The logistics of this were very in- facturing ideology is crucial in producing higher quality convenient as the complex we were in had two symmetrical products more efficiently. Further, the message being sent buildings with garage doors facing each other. “We had to current and potential customers becomes self-evident: two units on one side and one unit on the other, separated “Quality gears at quality prices.” by a driveway and parking lot. We were constantly walking Robust Gear’s commitment to research and develop- back and forth between the two buildings in the middle of ment has been ongoing since Anjan has been involved in winter,” recalls Anjan. running the company. Robust Gear specializes in shorter Anjan joined the business in 2007, on a full-time basis. runs, with jobs ranging between one to 500 pieces. Ac- Anjan had already spent his summers at the business during cording to Anjan, “It is in our best interests, as well as our high school and University. Just like his father, there was customers, to continue exploring ways of manufacturing no job that Anjan was not required to do. Being a taskmas- our wide array of products more economically without sac- ter, Sem expected his son to sweep floors, clean machines rificing our commitment to high quality. Our goal is to be along with learning every process from the ground up. innovative in using unconventional methods and processes

SEPTEMBER 2014 29 in churning out products manufactured on mers with 25 to 30 years of experience, and to the market and its requirements. We are conventional equipment. For example, the a conventional machinist with almost 25 passionate about providing quality prod- company has spent a considerable amount years of experience.” ucts: ISO 9000 quality while simultaneously of time researching on different ways to cut Robust Gear has an apprenticeship pro- maintaining competitive pricing without gear racks and worms on machines that are gram that provides employment oppor- sacrificing the highest standards of service not specifically designed for this use.” tunities to Oakville-area students whose in the industry. No job is too small. We will- Robust Gear owes its success to a team of interests lie specifically in becoming regis- ingly cooperate with our customers in show- seasoned professionals who are dedicated tered machinists. “Our company has been ing them and assisting them in developing to our company’s philosophy of making the instrumental in hiring numerous student calculations and drawings that will result in best product at the best price. “We currently machinists over the years” according to An- a precision product. In fact, we voluntarily employ 10 people,” said Anjan. “As plant jan. “We’ve provided extensive hands-on, provide our customers with necessary for- manager, Steward Lord has extensive expe- vocational training to these students. We mulas and information, to make calcula- rience in the manufacturing environment. encourage all new employees, hired as gen- tions required in the production process, Like my father, Stewart also completed his eral labourers, to enroll in an apprenticeship and present them directly on our website apprenticeship in England. He has worked program at a technical or vocational school. at www.robustgear.com. I encourage your in manufacturing environments in various As a result, numerous employees have re- readers to explore this and other valuable roles and industries in both the UK and ceived their trade certification while work- information on our website.” Canada. He has been a part of our team ing with us.” since February 2014 and has been instru- Robust Gear has been manufacturing FOR MORE INFORMATION: mental in Robust Gear obtaining the ISO high-quality custom precision gears and To learn more about Robust Gear’s products certification in July. The rest of our valuable machinery parts for almost 30 years. An- and services, visit them at robustgear.com, team consists of gear cutters with 40 years of jan maintains, “Our knowledge base and or call 800-661-4687. experience, CNC machinists and program- our list of products have grown in response

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Tests to reduce risk are used to build confidence in the design and analysis techniques before the final product reaches an aircraft.

By Scott R. Davidson and Jeffrey D. Hayes, The Boeing Company — Philadelphia WEIGHT REDUCTION IS OF GREAT IMPORTANCE IN THE DESIGN OF GEARING FOR AEROSPACE

APPLICATIONS. NATURAL RESONANCE RESPONSES OF THE GEAR HEAD AND SHAFT CHANGE

IN FREQUENCY AND AMPLITUDE AS WEIGHT IS REDUCED FOR AEROSPACE GEARS.

Care should be taken to understand the gear resonance A test was conducted to evaluate rapid prototyp- modes and compare the modes with operating speeds. ing techniques available on the market. A two-stage Modes should be evaluated and characterized by their idler gear was fabricated by using two different rapid impact on amplifying gear tooth root bending stresses. prototyping techniques. The two rapid-prototype test If not addressed, damaging modes could magnify specimens as well as the production part were rap tested fatigue bending stresses and cause tooth bending to experimentally determine resonant frequencies and Wfailures of the gear. Once determined, damaging modes mode shapes. FEA results were compared to the experi- can be shifted or gear damping techniques applied mental test results as well. The test gave us a chance to the design. Finite Element Analysis (FEA) is used to “try-out” rapid prototyped metal parts, now known to determine gear resonance frequencies, which are as ‘additive manufacturing’ and attempt to reduce a compared to the usage of the aerospace gear. portion of our risk reduction test time. This paper sum- Due to the costs and time involved in the design and marizes the testing conducted, FEA result predictions, build of an aerospace gearbox, tests to reduce risk are and compares rapid-prototype gears to production gear used to build confidence in the design and analysis resonance results. The modal excitation test, whether techniques before the final product reaches an aircraft. done on the production part late in the program or on In main power drive applications for helicopters as well rapid prototyping parts early in program verify that as aircraft mounted accessory drives, gear resonance the FEA analysis has been done correctly and reduce response tests, known as rap tests, are conducted to overall program risk. determine by test, the frequencies and shapes of gear resonance modes. Due to the long lead time involved in BACKGROUND manufacturing light weight, carburized steel gears, rap Aerospace gears are designed to be as light as possible tests are sometimes conducted on non-carburized test to transmit speed and torque from one location to parts that approximate the final shape of the completed another. Understanding loads and environment help gear design. In aerospace, our internal culture is one of to define a solution that minimizes weight and space demonstration of an acceptable design by test. We step required. Gear resonance excitation is a phenomenon through the gates shown in Figure 1 for a gear design where natural frequencies of the gear and shaft are as it relates to gear resonance. excited by operating speeds. Depending upon the mode The focus of this article is to reduce the time of step shape of the natural frequency, tooth root bending 3 validation of the FEA result and not on the overall stresses can be amplified beyond intended design lim- method used. Tests help to mitigate a potential cost its. If not accounted for during the design, unknown and scheduling debacle if damaging modes are not elevated bending stresses can lead to crack initiation in predicted correctly before the transmission enters test the gear tooth root and subsequent failure of torque and or service. All cost effective opportunities to reduce risk speed transmission. along the development process of aerospace gearing Analysis of gear resonance in the design stage con- should be taken advantage of, particularly those that sists of using FEA software to mesh three-dimensional can happen early in the development phase. computer-aided geometry and analyzing the geom-

Figure 1: Gear/gearshaft development for resonance.

Printed with permission of the copyright holder, the American Gear Manufacturers Association, 1001 N. Fairfax Street, Suite 500, Alexandria, Virginia 22314. Statements presented in this paper are those of the authors and may not represent the position or opinion of the AMERICAN GEAR MANUFACTURERS ASSOCIATION.

SEPTEMBER 2014 33 etry under different boundary conditions. diametral modes, which are largely unaf- the final part is fabricated on a test gear Traditionally, modal analysis of gears is fected by bearing support boundary condi- that is similar in geometry, stiffness and done using a free-free boundary condition. tions. Shaft modes that lie on or near gear density. In past efforts, rough test gear The main advantage to free-free analysis mesh frequencies can be further investi- geometry fabricated was a simplified ver- is the convenient comparison with experi- gated by performing frequency analysis sion of the final part minus gear teeth or mental test results, which are collected by of a finite element model with boundary other features (Reference 1). Part fabrica- suspending the test gear on elastic strings. conditions simulating bearing supports. tion was simplified to reduce the time The most damaging vibration modes of In order to verify analysis of the gear needed and traded for accuracy of predict- interest involve vibration of the gear in geometry, testing can be conducted before ing the final part gear resonance frequency and mode shapes. The goal of the rap test is to cost effectively validate the FEA results with a focus on not all the modes, but the ones that we believe amplify bending stress. With the evolution of computing power and FEA packages, increasingly complex parts with denser meshes can be analyzed that more closely match testing of final part geometries. On the manufacturing front, advancements in five axis machining and rapid prototyping, or additive manufacturing, hold promise for more accurate test gear geometries without sacrificing the fabrication time. TEST SPECIMEN DESIGN AND ANALYSIS FROM PROTOTYPE TO PRODUCTION A two stage spur gear design with an integral shaft was chosen for the test used in an aircraft transmission design. A cross section of the idler gear is shown in Figure 2. Basic parameters of the two gears are listed in Table 1.

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2014-502_004 LVT_010_EMO_GB.indd 1 18.06.14 15:03 Idler 4 Idler 5 Diametral pitch [1/inch] 10 10 Number of teeth 44 63 Pitch diameter [inches] 4.400 6.300 Face width [inch] 0.600 0.600 NOTE: Gear teeth and bearing races are carburized and ground. Table 1: Test gear description.

Test gear 1 Test gear 2 Aircraft gear Manufacturing process DMLS 5 axis CNC Conventional Figure 3: Direct metal laser sintering Figure 4: Five (5) axis CNC milled test part. test part. Material Maraging steel 1018 steel Pyrowear 53 steel the machine; in this case the volume was limited to 9 inches x 9 Modulus 23.5-29.5 Msi 29.0 Msi 29.0 Msi inches x 8 inches. Density 0.289-0.293 lb/in3 0.284 lb/in3 0.283 lb/in3 A second test gear was made of 1018 steel using a 5-axis Computer Numerical Controlled (CNC) milling operation, see Figure 4. The Part weight 5.9127 lbs 5.9859 lbs 5.9013 lbs computer aided design file was provided as a template for the mill- Table 2: Gear material properties. ing machine. The gear teeth were cut by electric discharge machining (EDM). Figure 5 shows the received test gear. For the resonance test, two rapid prototyping processes were The actual aircraft gear application is a carburized and hard- employed for the manufacturing of test gears. One test gear was ened gear made of Pyrowear 53 gear steel. The part was manufac- made using Direct Metal Laser Sintering (DMLS) technology, tured using conventional turning, hobbing, and grinding process- see Figure 3. DMLS is an additive manufacturing process where es. Figure 5 shows a picture of the aircraft gear used for the test. metal powder is deposited on a surface and made solid by the use Gear materials for the test were chosen to closely match the of a laser. Layers were deposited in 0.001 inch increments until the density of the final part configuration. Table 2 compares material entire part was created. Part size is limited to the dimensions of properties for the two test gears and the actual aircraft part.

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Havlik Ad 2014-08-12.indd 2 2014-08-12 7:24:13 AM Reference [2] provides guidance for classification of different mode shapes into three categories of increasing concern. Below summarizes the three categories presented in [2]:

• Insignificant modes – modes that are unlikely to magnify gear bending stress • Complex modes – modes that could be significant • Simple modes – modes that will magnify gear bending stress

Presented in Table 3 are descriptions and classifications of some Figure 5: Actual aircraft gear. Figure 6: Finite element mesh of gear. of the modes noted during the test.

An FEA analysis of the gear was performed using ABAQUS. TEST The solid geometry was taken directly from a Computer Aided A gear rap test was performed of each test gear configuration. The Design (CAD) model created in CATIA and imported into test setup consisted of suspending the test gear by a rubber cord. ABAQUS. The CAD model contained gear and spline teeth The gear was inspected by striking with an instrumented hammer that were modeled as involute teeth. After the gear geometry was at a prescribed location and then recording the response using an imported, a detailed mesh using 10-node quadratic tetrahedron accelerometer mounted on the part. This mimics an unsupported elements (C3D10) was constructed, as shown in Figure 6. gear configuration where the part is free from mounting con- A frequency analysis solution was run using the Lanczos straints known as a free-free rap test. A picture of the test setup is eigensolver method. Modes in the frequency range of 10 Hz to shown below in Figure 7. 20,000 Hz were extracted. Six rigid body modes, three rigid and A special instrumented hammer was used to apply a force to three rotational, at zero frequency were ignored. Only the lower the part. The accelerometer measured the magnitude of the load frequency mode of the orthogonal modes was processed. At this applied and acted as a trigger for the time measurement of the point, we need to address how to describe each shape. Shapes can response. An accelerometer to measure the response was chosen act individually or respond together at a particular frequency. based on the size of the part. The response accelerometer was

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40 gearsolutions.com moved between various predetermined positions while the ham- Response mer impacted the same location and direction. The accelerometer Locations Elastic Support was mounted on the web to measure axial response and then the test was repeated mounting the accelerometer on the gear tooth topland to measure radial response. A data analysis package was used to align the different responses and to provide a visual Accelerometer representation of the measured results. The goal of the test is to on Topland determine the frequency at which mode shapes occur. Not all mode shapes will be sought during the test. RESULTS Table 4 summarizes mode shapes and frequencies measured for the two rapid prototyping gear parts, the production aircraft part and the FEA results. The subject idler gear has two gears on a common shaft. The larger gear is labeled gear 5 and the smaller is labeled gear 4. The first column in Table 4 describes which gear was active in the Alternate: modal response for that frequency. When both gears were involved to Calibrated Impulse Accelerometer Hammer on Web a significant degree in the mode shape the “gear” is labeled 4/5. The second column in Table 4 describes the mode shape. Figure 7: Idler 4/5 gear in test setup. The first mode shape as represented in the test laboratory software is shown in Figure 8. frequencies measured on the aircraft part. The 5-axis CNC part produced responses with an average error of 2% greater than DISCUSSION OF RESULTS the aircraft part. The DMLS gear produced responses that were Results showed correlation between the FEA approach, the on average 9% lower than the production part. The lowest and DMLS test gear and the 5-axis CNC gear. The natural fre- highest deviations of the DMLS part from the aircraft part were quencies predicted by the FEA method were within 1% of the 8.28% and 10.29% respectively. Although this was not as accurate

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Table 3: Mode shapes.

Booth as the other methods from the absolute frequency stand point, N-7036 the DMLS gear natural frequencies were consistently lower than the production gear by roughly 9%. This is due to either a lower modulus of the DMLS maraging steel, a higher density or a combination of both. In natural frequency analysis, the ratio of the elastic modulus to the density of the material is a key parameter.

One can see from Table 4 that the modulus of the resulting DMLS part can vary significantly. For the parts made, the resul- tant volume was not measured, which is necessary to calculate the actual density of the DMLS part produced. The DMLS part results were much closer than we expected given the variability in the density and our initial concern over how the material might damp resonance response. (See Table 5). A summary of the deviations of natural frequencies from the baseline production part is shown in Table 6. It shows that the 5-axis CNC natural frequency results could be used without adjustment. The DMLS natural frequency results should be KAPP TECHNOLOGIES L.P. 2870 Wilderness Place Boulder, Colorado 80301 adjusted by a suitable factor to get a good estimation of what the Phone: 303 447-1130 [email protected] www.kapp-niles.com production part natural frequencies would be. Table 6 shows that

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Figure 8: Modal analysis software representation of experimentally measured AND REPEAT. web out of phase mode. Weldon Solutions. With cutting-edge cylindrical grinders that the DMLS natural frequencies are typically 9% low from the increase performance,’re in, turn enhanceto efficiency and production part studied, so factoring up the DMLS results by 9% you generate cost-effective processes, whatever would yield close to the production parts results, in this instance. “GEAR” The adjustment factor will be a function of the base powdered metal and the machine used to generate the 3D printed part, because they determine the ratio of elastic modulus to density in the part produced. CONCLUSIONS Using rapid-prototyping manufacturing methods, test specimens for gear resonance rap testing can be made in a timely fashion to determine experimentally mode shapes and frequencies. There is the potential for a reduction in test fabrication time by employing rapid prototyping of parts for the risk reduction test. ACKNOWLEDGEMENTS The authors would like to acknowledge the work and support of Charles Garmel, Christopher Pierce, Robert Fitzpatrick, Evan Filter, and the Boeing Commercial Airplanes Rapid Prototyping and Modelling Laboratory in Seattle, WA for this project. REFERENCES Visit us at IMTS 2014! 1. B.R. Uppaluri, B.W. Douglass, A Validated Finite Element Booth# N-6870 Frequency Response Criterion for Resonant-Free Gear Design For more information and to see demonstration of the V-22 Tiltrotor Aircraft presented at the 27th Joint videos, visit WeldonSolutions.com Propulsion Conference, June 24-26, 1991, Sacramento, CA, (AIAA 91-1908). 2. R.J. Drago, F.W. Brown, A.D. Sane, and D.M. Stremick, Gear Resonance Analysis Experience with F-22 AMAD, presented at the 7th International Power Transmission and Gearing Conference, October 6-9, 1996, San Diego, CA, (1556PTG96). 3. R.J. Drago and R.N. Margasahayam, Analysis of the Resonant Response of Helicopter Gears With the 3D Finite-Element QUALITY. Over and over again. Method, presented at the 1988 MSC/NASTRAN World User’s Conference, Los Angeles, CA, 1988.

44 gearsolutions.com Gear Mode shape FEA, Hz Production part, Hz DMLS part, Hz 5-axis CNC part, Hz

4/5 Web out of phase 1870 1854 1682 1872 5 2DR 2128 2145 1952 2193 4/5 UMB out of phase 2304 2291 2090 2325 4 2DR 3017 3032 2720 3115 4/5 In phase SR/2WB 3265 3260 2974 3301 4/5 UMB in phase 3418 3412 3097 3462 5 3DR 4150 N/A 3784 4291 5 4DR 7128 N/A 6500 7379 4 3DR 7312 7361 6647 7632 4/5 Higher order coupled SR/WB 9061 9072 8320 9263 5 5DR 10793 N/A 9855 11187 4 2DSB with coupled 2D/WB 12460 12513 11338 12727 4/5 In phase 2DSB+2WB+2D 12781 12843 11733 13132 4 4DR 13032 13128 11883 13652 5 2DSB with coupled 2D/WB 13979 14101 12933 14474 4/5 Coupled web expansion 18229 18221 16652 18571

Abbreviations: SR – shaft rocking #DR – diametral modes UMB – umbrella WB – web # is the number of nodal lines (i.e., 2, 3 etc.)

Table 4: Summary of mode shapes and frequencies measured for the three parts tested and FEA results.

3 Prototype method Material Density, ρ, lb/in Modulus, E, Msi

CNC machining Steel 1018 0.284 29.0

Direct metal laser sintering (DMLS) Maraging steel 0.289-0.293 23.5-29.5

Baseline production gear Pyrowear 53 steel 0.283 29.0

Table 5: Comparison of manufacturing methods.

Method: Average % error Minimum deviation Maximum deviation

FEA analysis -0.3% 0.9% -1.1%

Direct metal laser sintering (DMLS) -9.1% -8.3% -10.3%

5-axis CNC 2.2% 1.0% 4.0%

Table 6: Deviations from production part natural frequencies.

ABOUT THE AUTHORS

Scott R. Davidson is a gear technology engineer at The Boeing Company in Philadelphia, PA. He specializes in gear design, research, and analysis for rotorcraft drive and rotor systems and supports manufacturing of the U.S. Army CH-47 Chinook Helicopter and other aircraft programs. Jeffrey D. Hayes is an associate technical fellow within the Dynamic Component Stress group at The Boeing Company in Philadelphia, PA and specializes in bearing technology. Jeff has over 28 years of experience in aerospace as a stress analysis engineer of dynamic components used in rotorcraft drive and rotor systems.

SEPTEMBER 2014 45 Upgrading and Testing a 72,000 H.P. Gearbox

Transmitting 54 megawatts, or 72,000 horsepower, through one gear mesh at a pitch-line velocity of 29,000 feet per minute is not child’s play.

By Roland Ramberg The Gear Works Seattle ANOTHER DAY AT THE GEAR HOSPITAL OVER THE PAST 40 YEARS, WE HAVE HAD MANY GEARBOXES COME TO OUR DOOR THAT HAVE HAD CHRONIC, OPERATIONAL ISSUES IN NEED OF REMEDIAL TREATMENT. SOMETIMES, THE FIX IS STRAIGHTFORWARD, AND SOMETIMES IT’S PRETTY COMPLEX.

DESIGN MODEL analysis and logistical assistance for replacement gear This last year, The Gear Works became involved in a elements. In addition, Bob Errichello and Jane Muller gearbox repair and upgrade project that pushed the from GEARTECH of Townsend, MT. were contracted limits of our gear manufacturing and testing capabil- to perform a failure analysis of the failed gear sets ity, requiring the combined forces of some of the most and conduct a forensic review of the available inspec- respected engineers in our industry. The decision to tion reports, metallurgical lab results, and all original take on the project was based on a desire to increase our manufacturing documents. GEARTECH’s investiga- Oexperience and capacity in repairing high-speed, high- tion revealed that there were several failure modes. horsepower gear drives, while recognizing it had the The most prevalent root cause was the result of mate- potential of becoming the dreaded job from hell. Just rial transformation of the gear teeth, which over time like many gearbox projects, the customer had a pain- negatively affected the load distribution across the tooth ful history of failures and unsatisfactory performance mesh. This phenomena coupled with an imprecise helix before The Gear Works was finally contacted. modification severely reduced the tooth contact area. The saga began over ten years ago after a major oil In another incident, grind temper was discovered as the company commissioned a large Floating, Production cause of failure. Artec was contracted to procure a new Storage and Offloading (FPSO) vessel to pump crude replacement gear set from The Gear Works made to oil from submerged oil wells located in the North an upgraded design under the quality procedures and Atlantic. The ship is one of the largest ever built, requirements as directed by GEARTECH. The gears approximately the size of three football fields with the would be installed in a spare gear case, spin tested and capacity to store 960,000 barrels of oil. From a network delivered to the customer before the end of the 2013 of flexible flowlines protruding from a rotating collar at summer and the oncoming rough seas. the bottom of the hull, oil is pumped into onboard holding tanks and then offloaded onto shuttle tankers for THIS ISN’T GOING TO BE EASY shipment to refineries. The vessel is also equipped with Transmitting 54 megawatts, or 72,000 horsepower, a sophisticated global positioning system, plus bow and through one gear mesh at a pitch-line velocity of 29,000 stern thrusters, so its heading can be maintained into feet per minute (147 m/s) is not child’s play. Unforeseen the prevailing seas. The ship was designed and built to consequences can occur under these critical conditions. operate 24 hours a day for many months at a time. A Our advantage was that we knew from past experience centralized onboard electrical power station provides what didn’t work and that the end customer was com- all of the electricity required to power the production mitted to doing the job right. Reliability of the gearbox equipment and other ancillary demands of the vessel. trumped low bid. The ship is equipped with two enormous generators, The first task was to redesign the gears to mitigate the each driven by a Frame 6 gas turbine engine through a thermal effects operating along the 20.5” tooth width. 1.42 / 1 reduction gearbox. Each system can produce Because of the high RPM and the lower helix angle, the up to 54 megawatts, or enough onboard capacity to axial meshing velocity was in excess of Mach 3 causing power over 50,000 average households. churning, shearing and heating of the oil and air vapor as they were pumped along the face width of the gear. BRING IN THE EXPERTS The original O.E.M. unsuccessfully attempted to deal Not long after the ship began full operation, perfor- with this issue by providing a 2” relief gap, centered mance issues arose with the gearboxes resulting in mid-face. Using decade’s old research by the Maag multiple gear tooth failures. After several unsuccessful Gear Wheel Company and years of field observations attempts by the original equipment manufacturer to of single helical, high speed gearing contact patterns, correct the problems, the owners decided to contact Artec modified the pinion lead to compensate for the third-party experts. The firm of Artec Machine Systems non-linear thermal distortion and the torsional/bend- of North Brandford, CT. was hired to perform onboard ing deflections. The coast flanks were kept straight to inspections, technical field support, an engineering facilitate alignment in the field. The helix angle was Failed pinion onboard the FPSO vessel (note relief gap and varnishing increased from 8 degrees to 10 and the modular pitch due to overheating) was slightly reduced to maintain the original center dis-

SEPTEMBER 2014 47 tance. Tip relief on the gear and pinion was LET’S MAKE CHIPS added by GEARTECH. The gear geom- The manufacturing process began with etry changes resulted in a 20% reduction in procurement of special steel forgings the axial mesh velocity and eliminated the (18-CrNiMo-7-6) from Europe for the new need for the relief gap. gear and pinion. Strict chemical composi- The second task was to develop a set of tion and cleanliness specifications had to quality procedures that would dictate the be held along with a forging reduction manufacturing requirements and documen- requirement of 5:1 minimum. The forg- tation needed to assure the end customer ings were rough turned, magnetic particle that past quality issues could be avoided. and ultrasonic inspected for cracks and Several pre-production meetings were held inclusions before shipment to the U.S. at The Gear Works with a cadre of sea- with the certification of Lloyd’s Register. soned metallurgists, mechanical and test Upon receipt of the material in the plant, engineers, field technicians, and production customer pressure was high to keep the experts to add input to the quality proce- project on schedule through the machin- dures being compiled by GEARTECH. ing and gear cutting operations despite the The result was a phonebook-sized quality mountain of technical challenges. procedure manual, running several hun- To assure proper case hardening, distor- Sacrificial Test Gear was case hardened and cut into dred pages, citing dozens of specifications tion control and optimal stock removal, sections for metallurgical analysis and standards from organizations such as a sacrificial test gear was made with the AGMA, ISO, API, ASTM, ASM and SAE. same alloy and gear geometry as the rede- core properties at a metallurgical testing The manual became the gospel guiding signed low speed gear. The 4,000 pound laboratory. Those results helped predict The Gear Works in manufacturing, quality test gear was hobbed, tooth charted, and the reaction of the alloy to a specific oven assurance, and product testing throughout then case carburized by a pre-approved using a predetermined carburizing and the project. The scope of work also included vendor. Subsequently, the test piece was quench recipe. When the actual replace- a factory spin test of the new gear set before re-charted for distortion analysis and then ment gears were case hardened, the micro- final shipment. sectioned and inspected for surface and structure and hardness results were accu- rately forecasted and within the specified requirements. Gear tooth distortion was held within acceptable limits and mirrored the test gear fairly closely. Cuts More For Less! After post heat treat blank preparation, the tooth flanks were finished ground on a Gleason-Pfauter P1600G gear grinding machine to AGMA-A4 accuracy toler- • Program recommended cutting rates and • Decrease errors with auto- blade speeds based on material properties matic material width sensor ances. To minimize the risk of grind tem- • Exclusive Cosen V_Drive Technology • Blade Life Management for per (the gear man’s curse), CBN grinding decreases cutting time by 25%-50% up to 10 blades wheels were employed in lieu of dress- • Save-a-Blade Feature • Servo Downfeed System able vitrified wheels. Enhanced, pre-grind tooth mapping to identify the locations of maximum positive grind stock was also used. After the final grind and application of the topological lead modifications to the pinion flanks, the results were indepen- dently verified on a CNC gear analyzer in the Company’s temperature controlled metrology laboratory. Additionally, both gear elements were mounted in a roll stand to check for contact patterns on both loaded and unloaded gear flanks. These contact patterns were later used to confirm

16.9” Round proper mounting and alignment in the Programmable CNC Bandsaw gear case. The gear case was also inspected

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48 gearsolutions.com Preparing to grind topological lead and profile Tooth contact patterns were checked in the roll stand corrections into pinion

To check for grind temper, the gears The no-load spin testing proved to be utes. Easy to say, tough to do. Not look- underwent a nital-etch inspection per challenging, and expensive. To meet API ing for yet another reason to invest more ISO-14104 under the watchful eye of Bob testing requirements, the gearbox needed hard-earned capital into the business, The Errichello. Within four hours of complet- to be incrementally ramped up to the Gear Works forged ahead anyway with a ing the inspection, the gears were then operating output speed of 3600 rpm, held major upgrade to its test bench. To man- oven baked at 325 degrees F. to eliminate constant for 4 hours and then pushed to age the oil distribution system, the com- the risk of hydrogen embrittlement. After a 10% over-speed condition for 10 min- pany procured a 950 gallon reservoir, 6 some final machining, burnishing of proximity probe diameters and dynamic bal- ancing to API 613, the 8600 pound gear set was ready for assembly. SLEEPLESS IN SEATTLE The scope of work required that the gearbox be assembled and tested at The Gear Works per an extensive procedure provided by Artec. Because of its overall weight of 25,000 pounds, the gearbox was assembled on riser blocks mounted right on the test bench. In addition to the upgraded gears, the assembly required a replacement quill shaft, a new thrust retaining hub, new tilting pad radial bearings for the pinion and new journal bearings for the gear. Two new oil spray manifolds for the gear mesh were also designed and shop tested. Of the 65 gpm of turbine oil supplied to the gears, 20% was directed to the input mesh and 80% to the exiting mesh. Another 210 gpm of oil was provided to the bearings via a network of internal passages and external plumbing. The gearbox was also outfitted with 13 proximity probes and accelerom- eters plus 7 thermocouples. Throughout the assembly process, Artec provided invaluable, hands-on technical direction.

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Gearbox being assembled on test bench

large air-to-oil heat exchangers, and 3 large tional speed, ambient noise levels in the test pump packages at 50 H.P. each to supply, room and heat exchanger bay reached levels scavenge, circulate and filter the oil at a where ear protection was mandatory. To rate of 300 gallons per minute. To drive the mitigate complaints from the neighboring gearbox, a 1000 HP, 4160 volt motor and businesses, testing took place in the eve- a large variable frequency drive to control ning. Despite conservative estimates to size the speed was also purchased. Because all the test motor, 100% of motor rating was this equipment would be operating at the reached at 3600 rpm, and pushed to 130% same time, special permission was granted to meet the 10% over-speed condition. from the local utility to consume up to 4 Lesson learned: size the test motor at twice megawatts of power available to The Gear estimated load. Notwithstanding the chal- Works’ assembly facility. lenges, the gearbox operated very smoothly After several trial runs, official testing and within the specified vibration limits. took place in late summer of 2013 under After the test, the gearbox was partially dis- the witness of Lloyd’s Register. Artec took assembled and inspected for bearing wear responsibility to install and monitor the and gear tooth contact. Everything looked instrumentation while The Gear Works’ great. The gearbox was then shipped and test engineer and support staff manned successfully installed on the vessel with the the motor controls and cooling system. As oversight of an Artec engineer before the the RPM was slowly increased to opera- onslaught of inclement weather.

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BREAK OUT THE CHAMPAGNE? Six months after installing and operating the upgraded gearbox, a thorough inspection of the rotating elements was conducted by Artec onboard the FPSO vessel. To everyone’s delight, the vibration and temperature records revealed no indication of problems and the gears looked beautiful, showing no signs of distress. We are now looking forward to refurbishing a second gearbox to serve as a backup to the two in service. None of this would have been possible without the collaboration, coordination and close relationship between our company and the engineers at Artec Machine Systems and GEARTECH. I also owe a debt of gratitude to Mr. Richard Meredith of D.C. Energy who guided The Gear Works through the design and development of the test bench, and Mr. Rainer Eckert of Northwest Laboratories who rendered invaluable metallurgical expertise. With this close alli- ance and all this experienced talent, I see more extraordinary projects and sleepless nights ahead.

ABOUT THE AUTHOR As chairman and CEO, Roland Ramburg is responsible for the direction and long term strategic planning of the company. He is also actively involved in a leadership role with the American Gear Manufacturers Association (AGMA), and has served on its Board of Directors since 2006. From 1997 to 2002, Ramburg served as chairman of the Small Business Council and chairman of that organization’s awards sub-committee. Roland and his wife, Jean, have two grown children. For more information on The GearWorks Seattle, visit www.thegearworks.com

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54 gearsolutions.com We Know of Few Places Where Roughness Improves Performance.

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B O O T H 7 0 4 0 S E P T 8 - 1 3 Reishauer Corporation • (847) 888-3828 • www.reishauer.com UNIMILL: Prototype and Small Batch Bevel Gear Manufacturing

The UNIMILL method produces bevel gear geometries identical to those produced by face milling cutters.

By: Dr. Hermann J. Stadtfeld MANUFACTURING OF SPIRAL BEVEL AND HYPOID GEARS CAN BE CONDUCTED IN SEVERAL WAYS. THE FOLLOWING METHODS ARE COMMONLY KNOWN:

• Face hobbing with a circular face cutter, which rotates ending in the area of the 30° tangent point. Depending on the while the work rotates in the opposite direction (continu- severity and character of the undercut it is not possible to gen- ous indexing). erate this area precisely with correct normal vectors. Also the • Face hobbing with tapered hob (peripheral cutter), which slot bottom, connecting the fillet region from the 30° tangent rotates while the work rotates as well (continuous indexing). • Planing method with one or two tools, which move linearly, while the work either is performing a roll rotation or a combination of roll rotations and an additional rotation for a spiral shaped flank line (single indexing). M• Face milling, with circular face cutter, which rotates while the generating gear is not rotating. The work only performs a roll, but no indexing motion (single indexing). • Universal 5-axis milling with pencil shaped end mill (single slot manufacturing).

Methods A through D are well known and have been performed for more than 50 years. Method E became available with the possibility to enter complex free form surfaces into the control of 5-axis universal milling machines. While the manufacturing time is between 100 and 1000 times that of the processes A through D and the accuracy might generally be lower than that of the dedicated machines used to perform methods A through D, the advantage of 5-axis bevel gear machining is the flexibility. No special cutting tool is required and the bevel gear size is only limited by the size of the 5-axis Figure 1: Face cutter representing one tooth of a generating gear. machines available [1, 2]. A spherical or cylindrical shaped mill is used to shape the flank surfaces. The data post processing uses flank surface points and in some cases normal vectors to calculate the machining paths. The machining paths have to be close enough to achieve enveloping paths, which approximate the target surface precise enough. The orientation of the enveloping paths (flats) is only linked to the machining strategy, in order to minimize the machining time and the deviation from the target flank surface. It has to be considered that a generated bevel gear tooth consists of up to seven different areas: Figure 2: A typical cutting or grinding channel.

• Flank surface first flank • Flank surface second flank • Root fillet radius below first flank • Root fillet radius below second flank • Slot bottom between both root fillet radii • Undercut section below first flank and above root fillet • Undercut section below second flank and above root fillet

The true profile and lead generation according to the gearing law only works within the flank surface and in the root fillet area from the flank transition down towards the root bottom, (left) Milling of slotted nose piece with HSS disk cutter Figure 3: Conical milling tool. SEPTEMBER 2014 57 through the deepest bottom land to the opposite side root radius at the those three components. A spread blade face milling cutter envelopes 30° tangent cannot be generated using the common surface generating an outside cone and an inside cone which form a circular channel. Cup algorithm for bevel and hypoid gears. shaped grinding wheels are dimensioned to duplicate the cutting channel In case of face hobbed gears with extended toe or heel ends, it becomes for one particular gear design (stock allowance taken into account). also equally difficult or impossible to generate the extension of the flank A typical cutting or grinding channel is shown in Figure 2. Particularly surface, which in many cases does not consist of a true flank surface for large spiral bevel gear sets it is common to use pressure angles of 20 for according to the gearing law. One typical example is slotted nose pieces, concave and convex flanks. In such a case, outside and inside silhouettes which represent flank surface extension far behind the heel of the pinion of the cutting channel are cones that have angles of +20 and -20 relative to be clamped in front of the nose piece. However, those problem areas are to the axis of rotation. A tapered milling tool with a cone angle of 20 and formed with a face cutter head, which represents one tooth of the generat- a tip diameter with the value of the point width compared to the face mill ing gear exactly the same way, the generating gear in Figure 1 will form cutter head, would fit into the cutting channel. them: as undercut section, as root bottom area or as enveloping form cuts If the milling tool has an edge radius and a straight or curved profile beyond the theoretical face width. If the undercut, root bottom area etc. and additional features, then the cross sectional view of the milling tool are formed by the generating gear, then it is assured that rolling without can exactly duplicate the cross section of the cutting channel. Such a mill- disturbances between pinion and gear can occur. Undercut for example is ing tool can be positioned in the cutting spindle of a free form bevel gear not an “evil” caused by the manufacturing process, it rather is a geometri- cutting machine. The cutting machine axis could perform the regular cal necessity in order to assure correct rolling without interferences [3]. cycle of movements including the kinematical relationship of the work, as The solution for the problem areas is not a substitution of those sections it is performed in order to generate a bevel gear in the conventional face with plane, cylindrical or parabolic surface elements because of the risk of cutter head process. either weakening the teeth or causing rolling disturbances. However, the milling tool would in this case be located in the center of the face milling cutter. To duplicate the flank surface forming (cutting and UNIVERSAL METHOD DERIVED FROM FACE CUTTING generating) action, two additions to the standard setup and cutting cycle PROCESS are necessary to accommodate the pencil milling tool. First, the milling The face milling method defines flank surfaces dependent on basic settings tool is required to be moved to an offset location (“a” in Figure 4). The off- that define the relative location between a face cutter head, a generating set vector is identical to the average cutter point radius vector and can be gear axis and a work axis, as well as a kinematic relationship between located in the center of the tooth face width (point a in Figure 4). Second,

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For worldwide sales locations and additional information, visit: www.gleason.com • [email protected] program is the additional term shown in the formulas:

Figure 4: Pencil milling tool moved to offset location. the milling tool has to follow a circular arc in the plane of the face milling cutter. Figure 4 shows the case where the face milling cutter rotational plane is identical to the plane X-Z. The conventional cutting machine setup positions the cutter center at the position of the tip of the vector Ex (Figure 4) in order to use a tapered milling cutter, the center of the cutter spindle has to be positioned along the path of the arc b-a-c in Figure 4 and also move between the positions b-a-c (and reverse), while the cutting machine is in one roll position. In the next roll position the movement along b-a-c has to repeat. It is also possible to use a continuous slow roll motion, while the machine axes perform a fast pendulum motion of the tool center between b-a-c. In order to generate the profile of a tooth, the generating gear has to The cycle described can utilize a standard free form cutting machine rotate. This rotation is equal to a rotation of the vector Ex in Figure 4 with a standard cutting cycle. The only change vs. the conventional part about the axis Y (perpendicular to the drawing plane).

60 gearsolutions.com

Figure 5: Cutter blade silhouette and generating flats.

The introduced new process is called machine using an end mill according “UNIMILL™”. It can be performed to process E. At the same time, the on a regular free form bevel gear cut- gear accuracy of the inventive method ting machine. The infrastructure and is comparable to the process A and D accuracy level of the free form bevel due to the use of a gear machine tool gear machine are a desirable plat- concept. form for bevel gear cutting with the A third advantage of the UNIMILL UNIMILL process. method is the unlimited compatibility One advantage of the UNIMILL to the cutting and grinding with face method is the fact that it produces cutters. All existing design and optimi- identical bevel gear geometries as pro- zation computer programs can be used. duced with face milling cutters. Even Also the nominal data calculations, the generating flats have the same correction matrixes, are established characteristics and angular orientation and well proven correction software between the inventive method and the (G-AGE) can be applied without limi- face milling cutter method. Figure 5 tation. shows to the left a three dimensional Even in cased of unequal inside and representation of the conical milling outside blade angles of the analogue tool as it simulates the face cutter in face cutter process, a tapered milling one instantaneous roll position. Since cutter with half the included blade

the face cutter would produce in this angles (aIB + aOB)/2 as cone angle roll position one generating flat per can be used if the milling tool will be

flank (indicated on the outside silhou- inclined by kmill-tool = -(aIB + aOB)/2. ette in Figure 5), the tapered milling The calculation of the position of tool will produce the identical flat. As a tapered milling tool in the general the rolling motion progresses, further case can be calculated, based on the flats will be produced. Figure 5 shows geometric relationships of Figure 6 and to the right how the generating flat sec- 7 as follows: tions of the tool silhouette relate to the real generating flats on a flank surface. Input: The generating flat orientation of - Cutter tilt = Wx the 5-axis methods E are different - Cutter swivel = Wy to the face milling cutter method, - Mean cutter radius = Rw

which will introduce in many cased - Cutter phase angle reference value = αo

different roll conditions. The second - Cutter phase angle = αx advantage of the inventive method is - Roll position = q

the fact that standard cycles can be - Blade reference height = HR

applied (super-imposed by said pendu- - Sliding base position = XB lum motion) e.g. for soft cutting which - Additional milling tool inclination =

leads to manufacturing times of 10 to κMill_Tool 100 times that of the processes A and - Radial Setting = S D, which is in most cases only 10% of - Cutter Radius vector at reference posi-

the manufacturing time of a 5-axis tion = Rw(α0) 62 gearsolutions.com Figure 7: Triangular vector for generating bevel gears with tilted endmill.

After performing the transformations from conventional basic settings to the settings of a tapered mill cutting tool the following steps can be applied in order to prepare all data for the UMIMILL process:

Chose a number of roll positions that split qstart and qend e.g. in 50 increments:

→ q1, q2, q3 ... q51

where: q 1 = qstart ; q2 = qstart + Δq ; q3 = qstart + 2Δq ; q51 = qstart + 50Δq

Figure 6: Inclination of tapered milling tool. Δq => Δq = (qend – qstart)/50

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SEPTEMBER 2014 63 However, the discrete observation and processing of the roll positions lead to a looped data and position processing:

Roll position loop, q = qi , i = 1 to 51 I I Calculating current Ex and Ycut as function of qi I

I Cutter phase angle loop, α = αj, j = 1 to 201 I I Figure 8: Cylindrical tool, machining outside profile only.

I I Calculate current Rw and Ycutmill as

Apply for each roll position the formulas also be applied to the continuous indexing pro- function of qi and αj for the tool position, e.g. for 200 cess. The cutter rotation w is in a timed rela- I I increments: tionship to the work rotation, superimposed to I Continue next phase angle increment the roll motion on the work (in a continuous I

→ α1, α2, α3 ... α201 mode) or applied in discrete roll positions, simi- Continue next roll position

where: α1 = α0 – AF/2 ; α2 = α1 + Δα ; α3 lar to the previous explanations, where either

= α1 + 2Δα ; α201 = α1 + 200Δα roll and cutter rotation angle (equal tapered In both cases, continuous or single index

Δα = AF/200 mill position) have been observed in discrete machining, the last presented formulas are increments: valid and can be applied. Those formulas DATA PROCESSING FOR can be applied in case of an asymmetri-

GENERATION AND SWING MOTION ωwork = ΩCradle/RA + ω ZTool/ZWork cal cutting channel (Figure 6) as well as The described method was shown and or for a symmetrical cutting channel (Figure

explained for the single indexing process. It can δwork,i,j = δwork,start + qi/RA + αjZtool/Zwork 2). The symmetrical cutting channel only presents a special case of the more general

asymmetrical cutting channel (κmill_tool = 0). There are a multitude of possibilities to derive the formulas in order to position and Leader in spline move the tapered milling tool. However, rolling solutions trigonometric calculations would in their for 60 years. solution show intrinsic function depending We were the first to commer- on roll, tool rotation, and work rotation cialize spline rolling tech- angles as well as linear constants. The deri- nology in 1954. Since then vations shown here use the basic machine we’ve continued to innovate settings, which relate to the generating gear. with machines, tooling, and The resulting vectors Ex and Ycut can consultative support. mill mill be converted to basic settings:

2 2 Si = V Exx + Exz q = arctan(Ex /Ex ) Innovation – It’s How We Roll i x z XB,i = Exy

Wx,i = arccos(Ycutmill,y)

Wy,i = arctan( Ycut mill,x / Ycut mill,z) - qi

Additional basic settings, such as:

™ XP

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313-526-7865 do not change during the conversion from conventional tool to tapered mill. The basic

64US_Gear_GearSolutions gearsolutions.com ad JUL2014.indd 1 7/22/14 5:30 PM settings, as shown above can be converted into a 6-axes Phoenix® coordinate system. EXPANDING TO A VARIETY OF HIGHLY EFFICIENT TOOLS The UNIMILL machining method can be expanded to use a milling tool which is e.g. cylindrical and only machines one flank surface e.g. the outside flank like shown in Figure 8. The tool inclination angle in this case is -αOB. The maximal diameter of such a tool is limited as shown in Figure 8. A diameter larger than shown in Figure 8 causes mutilation of the opposite flank (inside flank). It is possible with such a cylindrical tool to machine the opposite flank in a second set of machining passes, if the sign of the tool inclination angle is changed (+αOB). For correct definition it should be stated, that the vector RW2 points to the centerline of the reference profile. Its preferred location is in the center of the tooth, in case of asymmetric pressure angles it is located radial in order to split the point width of the reference profile in two equal parts. The point width is the width of the bottom of the reference channel, in an axial plane in case of face milling cutters, in the offset plane in case of face hobbing cutters. The milling tool can be located using different references, which has no effect on the functionality of the inventive method. If the tool diameter is increased to a certain extent it becomes possible to machine the second flank (IB) simultaneously to the first (OB-flank—see Figure 9). Figure 9: Cylindrical tool with conical inside profile.

SEPTEMBER 2014 65 Figure 10: Cylindrical tool with conical inside profile and larger diameter in order to avoid mutilation.

However, in order to machine a flank intersects with the original tool axis in

without mutilation, the requirement regard- point Pρ. Pρ is determined as the origin of

ing the curvature radius is as follows: ρminOB. ρIB > ρmaxIB is always given in such a case. Figure 11 shows machining tool

ρOB Tip < ρminOB (given in Figure 9) geometries based on κmill_tool = -60º, -70º

ρOB Flank < ρmaxOB (given in Figure 9) and -90º. κmill_tool = -90º is an interesting

ρIB Tip > ρmaxIB (not given in Figure 9) special case of a peripheral tool.

ρIB Flank > ρminIB (not given in Figure 9) In every case in Figure 11 (cases 5, 6,

and 7) the vector ρminOB was constructed The diameter of the cutting tool has to be first. It has an intersection with the face

increased until the axis of rotation crosses cutter tool axis in point Pρ. The chosen

the origin of ρminOB (intersection with origi- milling tool inclination angle κmill_tool

nal cutting tool axis). In such a case, ρIB Tip leads in Figure 11 to a tool axis, which

= ρmaxIB and ρIB Flank > ρminIB applies (Figure crosses the face cutter tool axis in point

10). κmill_tool in Figure 10 is still -αOB like Pρ. This leads to the smallest possible

in Figure 8. Different angles of κmill_tool milling tool diameter which fulfills the can be realized, if the axis of rotation requirements:

66 gearsolutions.com No room for error?

For gears they can rely on, partner with a heat treater that you can rely on.

At Solar Atmospheres, your critical specs get the specialized expertise they deserve. From stress relief to case hardening, we’ll help assure that your gears can go the distance. Precise carbon control and aerospace- www.solaratm.com qualified pyrometry produce uncompromised quality. 1-855-WE-HEAT-IT Harness our leading-edge vacuum technology to improve the uniformity of your case depths, minimize distortion and enjoy clean parts with no IGO (intergranular oxidation). ISO 9001 / AS 9100, Nadcap accredited. Vacuum Heat treating Brazing CarBurizing nitriding Figure 12: Variety of UNIMILL™ tools

lowest tool investment (see Figure 12, right side and middle). Multi start fly cutters, which are similar to bevel gear chamfer cutters present certain restrictions regarding blade point width and edge radius due to the use of standard inserts (Figure 12, left side). Flared disc cutters which use custom Inserts are also available [4]. The advantage of tapered end mills is the fact Figure 11: Manifold of tools by increasing tool inclination angle, that most gear manufacturers can find nearby local tool shops that can leading to a pure peripheral cutting tool manufacture a new milling tool from carbide material including coating in less than two weeks. The basic dimensions of a tapered end mill are

ρ OB Tip < ρminOB (in Figure 11 ρOB Tip = ρminOB) point with, edge radius and included angle of the taper.

ρOB Flank < ρmaxOB (given in Figure 11) The cutting scenario of a face hobbed hypoid pinion is shown at the left

ρIB Tip > ρmaxIB (given in Figure 11) side of Figure 13. The end mill moves from heel to toe while it is milling

ρIB Flank > ρminIB (given in Figure 11) one generating flat at the convex pinion flank. After the end mill exits the slot at the toe, the machine axes set over to the concave side in order to PRACTICAL EXPERIENCES machine the corresponding drive side generating flat. If UNIMILL is utilized as a prototyping method, the use of disk The movement along the face width is called “swing motion”. cutters is most productive but the use of tapered end mills requires the Changing the swing motion between start and end roll position is pos-

68 gearsolutions.com sible in three sections, depending on the different chip load in the different areas. After a part is finished, a coordinate measurement is conducted and in case of significant deviations between nominal and actual flank, G-AGE™ corrections are calculated and sent via network to the Phoenix® machine control. Similar to the procedure in conventional bevel gear Figure 13: Milling of a face hobbed hypoid pinion (left) and a slotted nose piece (right). manufacturing, the corrections are applied in a menu to the basic settings and the UNIMILL software converts the basic settings in a part program with axes motion commands. In Figure 14 the scenario of a nose piece milling with a disk shaped HSS cutter is shown. In the case of nose pieces, disk cutters are very beneficial. The slots are nor- RARE mally very wide and the root fillet radius can be standardized because root bending GLEASON strength is not a criteria for those parts. Today, all the UNIMILL software is Gear Machine implemented in the machine control. The control computer receives a download file OFFERING which includes basic settings with gear Owned By And Surplus To The Needs Of Major Gear Manufacturer blank data, very similar to regular bevel gear machining. The operator screen allows to enter speeds and feeds, as well ONLINE ONLY as the number of generating flats and over AUCTION travel amounts etc. September 2 – September 18 A variety of different parts, manufac- Machines Available For Inspection tured with UNIMILL is shown in Figure 15. In addition to spiral bevel and hypoid gears, milling of straight bevel gears has also been developed and tested. In case of straight bevel gears, in addition to prototype manufacturing, the possibility of machining parts with a front bearing hub is attractive for the manufacturer. Auction To Include: Those parts have been manufactured in - (2) Gleason 608 Spiral Bevel Ring Gear Roughers the past with two tool generators, which - (2) Gleason 609 Spiral Bevel Ring Gear Finishers only deliver medium quality in a rather - Large Assortment Of Index Plates And Geneva Cams - For Gleason 608’s And 609’s slow process. Often, the material of solid - (4) Gleason 26 Spiral Bevel Gear Generators parts with integrated front hub is difficult - (2) Gleason 116 Spiral Bevel Generators - (1) Gleason 114 Straight Bevel Generator to machine because of a high strength - (1) Gleason 503 Bevel Gear Lapper requirement. The possibility to use coated - (1) Gleason 17A Bevel Gear Tester carbide tools in UNIMILL gives manufacturers an incentive to replace their aged two tool generators with modern CNC equipment allowing for a state of the art closed loop manufacturing. The straight bevel gear in Figure 15 requires a manufacturing time of 2 hours with a tool life of Phone: 513-587-2399 8 parts. The tools can be re-sharpened up www.mohawkmachineryliquidators.com to 10 times until they have to be replaced.

SEPTEMBER 2014 69 Figure 14: SUMMARY Different UNIMILL is a milling method for the manu- gear typed machined with facture of prototype bevel gears using end the UNIMILL™ mills or disk cutters. The UNIMILL software process requires basic selling in form of SPA of AAA files as an input. Additional input items like speeds and feeds, number of generating flats, over travel amounts etc. are entered into the process parameter input screen directly on the Phoenix® cutting machine. If high RPM’s are required like in case of tapered end mills, it is possible to use Phoenix® grinding machines or cutting machines with Willman. The Source for high performance castings. high speed spindles. In contrast to general multi axes machining which utilizes surface coordinates and normal vectors, UNIMILL does not depend on certain grid specifications and definitions Gear Hub Casting Planet Carrier Austempered Ductile Transmission Housing Planetary Gearbox Housing 4200 lbs Iron 450 lbs 720 lbs 7500 lbs about undercut and root fillet (which are difficult to obtain). UNIMILL tools follow the path of a face cutter head silhouette, while the face cutter is performing a generating (or form cutting) motion. The result is a faster process with surface finish characteristics very similar to the traditional cutting process. UNIMILL is available on all PhoenixII NEED FAST DELIVERY cutting and grinding machines as well as on all later models. “OF HIGH QUALITY LITERATURE PRODUCTION [1] Tsuji, I. Validation and Effectiveness of Machining the Teeth of large Size Gear Pairs with CASTINGS UP TO Intersecting Axes using a Machining Center Dissertation, University of 40,000 LBS? Tokyo, 2014 [2] Jaster, M. The latest in Big Gear GIVE US A CALL! Machining with DMG/Mori Seiki Gear Technology, Jan./Feb. 2012, ” Pages 42-44 Fast Turnaround • Flask Sizes-24” X 24” thru 144” X 144” Green Sand Molding and No-Bake Floor Molding • Production Quantities • Small Prototype Runs [3] Stadtfeld, H.J. Handbook of Bevel Meehanite Metal, Ductile Iron, High Silicon Ductile, Austempered Ductile, All Classes of Gray Iron and Hypoid Gears - Calculation, Manufacturing and Optimization Fast Quotes, High Quality, Reliable Service Rochester Institute of Technology, In addition, Willman offers Production capacity for components up to 40,000 lbs. and facilities for Rochester, New York 1993 patternmaking, heat treating and machining. Please visit us on the web: www.willmanind.com [4] Wermeister, G. Milling Tools for Bevel Gears Gear Solutions, April, 2011, Pages 48-52

ABOUT THE AUTHOR Quality You Can Count On Today...and Tomorrow Dr. Hermann J. Stadtfeld is vice president of bevel gear technology at the Gleason 338 South Main St., Cedar Grove, WI 53013 • Tel. (920) 668-8526 Fax. (920) 668-8998 Corporation. Go to www.gleason.com to E-mail: [email protected] Web Site: www.willmanind.com learn more.

70 gearsolutions.com

A New Innovation in Spline Rolling Rack Tooling

The R/C Rack System is the first major innovation in spline rack tooling since the inception of the process 60 years ago.

By Mike Callesen THE SPLINE ROLLING PROCESS WAS INVENTED BY THE MICHIGAN TOOL COMPANY IN 1954. THE TOOLS USED FOR THE PROCESS, COMMONLY REFERRED TO AS SPLINE RACKS, ARE SOLID PIECES OF TOOTHED TOOL STEEL DESIGNED IN SUCH A MANNER AS TO COLD FORM THE APPROPRIATE NUMBER OF EXTERNAL INVOLUTE SPLINE TEETH ON A WORK PIECE, TYPICALLY A SHAFT. SPLINE RACKS CAN BE REFORMED SEVERAL TIMES OVER THE COURSE OF THEIR LIFE.

The number of regrinds is dependent on several factors, includ- over the years, but, due to the large separating forces that can ing the pitch, pressure angle, and number of teeth of the spline, be encountered; the success has been sporadic at best. severity of damage, and machine parameters. Reforming US Gear Tools, a direct descendant of the original Michigan involves sending the used set of spline racks back to the Tool Company, recognized these problems and endeavored to manufacturer where the old form is completely removed design a new type of spline rack in order to address them. The and a new rack form is ground in its place. The resulting goals of the design program were (in order of importance): Tdifference in rack height is made up by means of a shim that is installed under the rack when it’s re-installed in • Ensure the same level of quality as is produced from current the customer’s spline rolling machine. spline racks. This approach to spline rack tooling created several • Create a “one use” spline rack that could be shipped to any issues with which the user had to contend. The float of market in the world from our manufacturing facility in the tools had to be managed to ensure there were always United States, preferably via Fedex or UPS. racks available when a tool change was required. This • Achieve the same tool life as current spline racks. involves keeping track of tools out for reform and track- • Make the system “quick change” and able to be utilized in ing the logistics of shipping to and from their regrind existing spline rolling machines anywhere in the world with- supplier. Also, due to the fact that it takes roughly twice out modification of the machine fixture. the time to manufacture new racks as it does to have an existing set reformed, the number of regrinds for each set The decision was made to enlist an outside engineering must be tracked so new tools could be ordered in antici- firm to assist in the design process in order to assure the pation of scrappage in the existing float. In an era when resources would be available to keep the project moving for- most high production facilities use predominantly throw ward. Verstand Engineering of Madison Heights, Michigan away tools, the tracking requirements can be an onerous was chosen as the design partner. The design had to rigidly task for plant tool management personnel not used to this and precisely locate the rack inserts in three planes in order to type of requirement. duplicate the performance of a solid set of racks. It was decided The logistics issues became much more acute with that the racks and carriages would utilize matched cross keys the dispersion of manufacturing facilities across the to control the primary horizontal location that determines tim- globe. Shipping times that have been measured in days ing of the set. The vertical plane would be controlled by surface domestically were now were measured in weeks. The ground bearing rails that would be qualified on both carriages paperwork and reporting requirements of dealing with after assembly to ensure precise location. The horizontal depth customs further complicates the regrind process. In would be controlled by utilizing the area between the bearing response, spline rack users have had to increase their rails as a key. The inserts would be clamped by means of four floats to compensate or risk running out of tools. Spline clamping pins (in the case of 24” tools) that would fit into wood- rack manufacturers have had difficulty becoming truly ruff key slots machined into the inserts. global suppliers without establishing facilities in each The design approach was to choose materials and heat treat market they wish to participate in, a daunting proposi- based on the lowest cost that was considered feasible. Changes tion considering the equipment and technical expertise that added cost would be made only on the basis of test results. required for each facility. The Alpha prototype was chosen based on an existing spline From a production standpoint, spline rolling machines rack used by a customer close to US Gear Tools Swannanoa, have a reputation as reliable, relatively low maintenance North Carolina facility. The design was reviewed within the pieces of equipment. Their Achilles heel, however, is company and released for prototype manufacture. changeover time. Spline rollers are not designed to be Two phases of testing were scheduled. The initial test was “quick change”. It is typical for tool change time to range done at US Gear Tools Swannanoa, North Carolina facil- from one hour to as much as a complete production shift, ity. The primary purpose was to evaluate whether the design depending upon the complexity of the setup and other fac- would duplicate the quality performance of the standard rack. tors within the production facility. Several spline rolling A sample of sixty pieces was spline rolled off of a standard machine providers have attempted quick change fixtures rack then measured for dimension over pins, lead, involute

SEPTEMBER 2014 73 sive load, had brinelled .0002” in the area where the maximum forces are encountered. This was worrisome after only 60 parts, given that rack life is typically measured in tens of thousands of pieces. It was also noted that because the rack insert was the same length as the carriage, there was not enough clearance to remove it with the carriage in the rack fixture of the machine, negating the goal of a quick change tool. It was decided to incorporate a design change to slightly shorten the rack insert, thereby allowing it to be installed with the carriage fixtured in the machine. The carriage itself was also modified based of potential fixturing anomalies that could be encountered on individual machines. The Beta prototype was then released for production. and index error to establish the quality baseline. ratios of each group, based on dimension The second phase of testing was per- The same machine was then changed over to over pins, were statistically identical. The formed in the customer’s facility. The Beta the new design and another sample of sixty first goal of the project, no reduction in part tool was set up on a machine in a production pieces were rolled. These parts were evalu- quality, was realized. line producing 3,500 parts per day. The tool ated in the same manner as the first group. The carriages were then disassembled life of standard racks on this line is generally There were no changes in the form charac- and inspected. It was noted that the bearing 25,000 to 30,000 pieces. The Beta tool was teristics of the splines. Further, the capability rails, which take the brunt of the compres- set up in the presence of USGT personnel.

· Custom gear racks in AMERICAN and METRIC standards, STRAIGHT and HELICAL, VARIOUS materials, FINE and COARSE pitch (254 D.P. – 0.5 D.P.; 0.10 Module – 50 Module); hard-cut (up to 60 Rc) and soft-cut (up to 40 Rc); 32” face width; Up to 82” lengths – longer lengths through resetting · Custom gears in AMERICAN and METRIC standards (3 D.P. – 72 D.P., 10” Diameter) · Precision Quality up to AGMA 12 · Prototype & Production quantities · Breakdown Service Available · Reverse Engineering · Unique Tooth Configurations · Heat Treating · Complete CNC Machining

74 gearsolutions.com The part quality was excellent, as expected. After producing 30,000 pieces over the course of the next couple of weeks, the Beta rack was removed by the customer and sent back for evaluation. The inspection result was surprising. The rack insert showed no appreciable wear or damage. Normally a set of racks at 30,000 pieces would show extensive chipping. It was decided to send the same set back to be run until the life was exhausted. A second set was also included so the customer could perform a changeover. It was also noted that the brinelling issue was still a concern on the carriage bearing rails however; .0004” deformity was observed. The good news was that it didn’t adversely affect part quality, but would continue to be closely monitored. Upon receipt, the customer elected to put the unused rack insert in. Again, the results were surprising; 56,000+ pieces were produced. This was unheard of for this application. The used insert was reinstalled and ran to 45,000 pieces before several oversize parts were run through it, destroying the racks (but not damaging the carriages). Inspection after these two runs revealed the bearing rail brinelling issue was continuing to degrade, necessitating a design change to a through hardened tool steel. Several more runs were performed with the new rails, which solved the bearing rail brinelling problem. Tool life continued to be stellar, with one set of inserts reaching 69,000 pieces. The overall average was 57,000, double the existing standard spline rack life. Several more design tweaks were implemented during testing at the suggestion of the customer’s production personnel, such as a screwdriver slot to aid in the removal of the insert from the carriage and tamper proof assembly screws. The documented changeover time was under ten minutes over the course of the test. After 250,000+ parts were produced, the testing was declared over. The four original goals were satisfied. Once the product development was complete, the focus turned to manufacturing. Standard racks are only green machined and heat treated once, then reground several times. In order for the new rack insert, which must be green machined and heat treated every time, to effectively compete with the existing business model, the insert cost was going have to approach the average use standard rack cost, as denoted by the formula:

SEPTEMBER 2014 75 New Rack Cost + The carriage is considered to be durable tooling. It is engineered to (Number of Regrinds x Regrind Cost) withstand one million cycles before needing rebuild. Many of the wear Number of Regrinds + 1 components are also replaceable in the field. The plan is to allow customers to exchange worn carriages for a “core charge” on the purchase of a Only by keeping common platform dimensions and mass pro- new or rebuilt set of carriages. Because all carriages of a given rack length ducing the inserts could this be done. Much effort was exerted to are of the same dimensions, they can be stocked for customer exchange. reduce the perishable (insert) cost. Alternate production methods Paul Simon, the CEO of US Group, the owner of US Gear Tools, were investigated in hopes of reducing the throughput time without named the tool “The R/C Rack System”. The “R” stands for Roto-Flo, sacrificing the gage level tolerances required. A series of prototype the trade name of the spline rolling machine division of US Group and inserts were made utilizing different production methods to evalu- also the original name given to the spline rolling process by Michigan ate the production cost involved in each. The final process utilized Tool Company. The “C” was designated for the author of this article. state of the art machining methods never before used in spline Currently, R/C racks are available in 24” and 13” lengths only. Plans are rack manufacture that significantly reduced the throughput time. underway to begin testing a 48” version late in 2014 or early 2015. The reduction in set up and processing time brought the insert The R/C Rack System is the first major innovation in spline rack price down to where, when coupled with the reduction in shipping tooling since the inception of the process 60 years ago. It promises to expenses and machine set up time, made them extremely competi- revolutionize the industry and will provide US Gear Tools access to the tive. The documented increase in tool life, which is fully expected global spline rack market from its single manufacturing plant in the United to occur in varying degrees in every application, further enhances States. US Gear Tools and Roto-Flo will be exhibiting at the IMTS the attractiveness to the customer. It is expected that the perishable Show in Chicago. A set of R/C Racks will be on display. Please feel tool cost per piece will be dramatically reduced, given the addi- free to stop by and see firsthand the next big leap in spline rolling tional rack life. technology.

ABOUT THE AUTHOR Mike Callesen has been with US Gear Tools/Roto-Flo for a over four years, having spent 30 years associated with a competitor in the spline rolling industry. He has been involved with the spline rolling industry for over 34 years. For more information, visit usgeartools.com.

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76 gearsolutions.com PRODUCT SHOWCASE New products, equipment, and resources Advanced CNC Systems from NUM Extend Competitive Edge

Advanced CNC systems from NUM are helping U.S. machine tool manufacturer Bourn & Koch, Inc. to extend its competitive edge in the market by using state-of-the art machine control software. Following a highly successful project to migrate control of powerful 7-axis horizontal gear hobbers to NUM’s Flexium CNC platform, the company is now standardizing on this control technology for an extensive range of its gear production machines. Bourn & Koch chose to upgrade to NUM’s Flexium CNC on its 25H - 400H Series II gear hobbers, starting with the 400H. The speed and power of this machine mean that it can replace as many as seven older style gear production machines, making it a popular choice with companies machining large precision components such as bull and cluster gears, worms, shafts, splines and pinions. Capable of accommodating work pieces up to 400 mm (16 in) in diameter, the 400H has an axial travel capability of 1,168 mm (46 inch) as standard and can be customized for the production of even longer parts. Both companies and their customers benefit from this collaboration. Jointly-developed conversational software has been cited by a number of Bourn & Koch customers as a factor in their machine purchasing decisions. For more information about CNC systems from NUM, visit www.NUM.com.

SEPTEMBER 2014 77 Bourn & Koch Add to Gear Shaper Offering

The Bourn & Koch Fellows HS2550- drive workspindle, electronic index drive 600 CNC Hydrostroke™ Gear Shaper for synchronization of cutter and work is a true bridge type 100” gear shaper rotation, CNC helix control, and CNC with a 0” center distance reach even linear backoff for independent control when the outside diameter of the gear of the backoff amount of each cutter is 100”. A 24” (600 mm) stroke length (which allows for crowning, tapering and allows long face width capability with a tool depth matching). The HDS1600- CNC controlled spindle for programming 300 reduces traditional mechanical stroke positioning, stroke length, and herringbone shaper setup and cutting stroking speeds in both the down and times significantly while offering a up motion for quick return rates, with verifiable consistent quality improvement positioning above the worktable via a to AGMA 10 or better. The machine is vertical slide of 17” (471 mm). The rated for 2 DP (12.7 module) gears, up six-axis machine is rated for 1 DP (25 to 40° helix angle, 60” diameter and is module) gear cutting. An optional feature, arranged for pinions and bullgears with CNC controlled crowning and taper for minimal changeover required. Multiple internal and external gears via servo machines are already in production control, includes software using Bourn at manufacturers of gearboxes in the & Koch’s Oriented Stiffness Back-Off™. artificial lift industry. The Bourn & Koch HDS1600-300 The HDS1600-300, when combined CNC Horizontal Double Helical and with Star SU’s Star PTG1 Tool & Cutter Herringbone Gear Shaper fills a void Resharpening Machine for consistent left by the Sykes herringbone gear grinding of accurate Sykes style shaper shaper, the last produced machine being cutter relief lips, further improves delivered ca. 1983. tool performance and accuracy of the The HDS1600-300 is a 9-axis, CNC process. controlled machine, with linear direct For more information, visit www. drive stroking of both heads, direct bourn-koch.com. 78 gearsolutions.com GCH Tool Group Announces Release of Centerless Grinder Guide

GCH Tool Group, the world’s largest supplier of spare parts, components and assemblies for centerless, ID, OD, double disc and surface grinders, is pleased to announce the release of its centerless grinder guide. This 16-page, full-color guide presents an “at-a-glance” snapshot of the company’s main offerings. “Our new guide shows the depth of our inventory,” says Dan Geddes, GCH Tool Group president. “No one in the world has a larger inventory of new parts and components than GCH. Because we’re grinder experts, we’re able to partner with customers whether they’re seeking a component or spare part for a grinder, or looking to improve a process.” Along with product offerings, the guide also includes information on GCH’s exclusive remanufacturing exchange program, the company’s best-in-class in-house metrology laboratory, and grinder upgrades and accessories. The guide features an array of vivid photos and easy-to-read text. The guide is available electronically as a PDF file or in print. To receive a copy, please call (586) 777-6250 or email [email protected].

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Hera USED Our line of new Hera cnc gear hobbers, manufactured by Yunil Machinery Mfg. Co., combines high quality and efficiency with affordable pricing. Since its inception in 1963, Yunil Machinery has specialized in the manufacturing of gear machines. Their 6 axis gear hobbing machine has been the most favored product, globally. Based on 40 years of knowledge and experience, Yunil developed the HERA series CNC hobbing machine line. The combination of quality components, exceptional craftsmanship, and We understand each of our customers have unique gear cut- flexibility in design make this full line of horizontal and vertical ting requirements, that is why we carry such a large gear machines tough to beat. machine inventory. We carry such brands as Gleason, G&E, Fellows, Barber Colman, Liebherr, Pfauter, and many more. You will find hundreds of machines on our website at all times; from gear cutting machines to finishing and inspection machines. Don’t forget, if you can’t find what you need on our website, let us know and we can try and find it for you. Service Fellows Remanufactured

At R.P. Machine, we understand that it’s about more than supplying gear machines. That’s why we provide a wide range of service on many types of machine tools. Our state- of-the-art facility and experienced staff allow us to handle service of all sizes. Our service abilities do not stop at just gear equipment, we can also assist you with machines such as large capacity lathes and mills, no matter the size. We offer preventive maintenance packages, rebuild- Keep pace with technology advances - without the expense of buy- ing and corrective service, retrofitting, machine and plant ing new equipment - with our full line of Fellows remanufactured relocation, training, and replacement parts. Our goal is to CNC gear shapers. These gear shapers are completely remanufac- provide the highest quality of service so each of our cus- tured using the latest components from manufacturers such as tomers can achieve their maximum production potential. Heidenhain, FANUC, Allen Bradley, and many others. Each machine is equipped with a new reliable CNC control with all the latest technology. These solid core machines are brought up to date with many additional options available. Each machine is remanufactured to 866.256.3708 your individual part requirements. 820 Cochran Street • Statesville, NC 28677 F: 704.872.5777 • [email protected] • www.rpmachine.com

TTi

Since its establishment in 1972, Tokyo Technical Instruments Inc. (TTi) has been dedicated to the manufacturing of gear measuring instruments. We are proud to be the official North American distributor of this extensive line of inspection equipment. The TTi line of gear inspection equipment can be found in manufacturing facilities all over the world, proven to be high quality and long lasting machines. TTi maintains their products from the development of the program software to the aftercare maintenance. With patented software and components, the TTi product line is sure to become the industry leader.

G&E Gould & Eberhardt is a pioneer in highspeed gear gashing with large diameter carbide-inserted cutters. Our new line of machines has a rigid design and heads engineered with state of the art gear gashing cutter technology. The exceptional results achieved in gear gashing technology have opened a wide range of applications for gear cutting in wind energy, mining, off highway construction and other coarse pitch gearing.

Booth #N-7030

866.256.3708 820 Cochran Street • Statesville, NC 28677 F: 704.872.5777 • [email protected] • www.rpmachine.com BARBER-COLMAN 16-16, S/N 3660, ’57 Sgl Thrd REF#104 BARBER-COLMAN 16-16, S/N 4136, Dbl Thrd, “C” Style End Brace w/Diff REF#104 BARBER-COLMAN 16-16 Multicycle, S/N 4170, Dbl Thrd w/Jump Cut Cycle “ C” Style REF#104 BARBER-COLMAN 16-16, S/N 4473, ’73 4-Thrd w/Workclamp Cyl “C” Style REF#104 MACHINERYGear Solutions BARBER-COLMAN 16-16 Multicycle, S/N 4520, ’75 Dbl Thrd w/Gooseneck Slide REF#104 Contact at BARBER-COLMAN 16-16 Multicycle, S/N 4631, ’79 “C” Style End Brace, 4W Adj Ctr REF#104 800-366-2185 to list your machinery. BARBER-COLMAN AHM (36”), S/N 1152, ’42 Dbl Thrd REF#104 BARBER-COLMAN 16-36, S/N 4090, ’66 Dbl Thrd, “C” Style End Brace REF#104 BARBER-COLMAN #16-16, Multi-Cycle, Dual Thread Worm and/or Single Thread Worm BARBER-COLMAN 16-36 Multicycle, S/N 4232, ’68 Dbl Thrd “C” Style End Brace w/Diff REF#103 REF#104 FEATUREDSUPPLIERS G&E #48H 48” Dia, 18” Face 2 DP, Universal REF#103 BARBER-COLMAN 16-56, S/N 3136R84, ’53 (Reb ’84), Dbl Thrd REF#104 G&E #48H, 48” Dia, 35” Face, 3 DP, Gooseneck Attachment REF#103 BARBER-COLMAN 10-20, S/N 6700045890, ’76 Dbl Thrd w/2 Cut Cycle REF#104 Midwest Gear Corporation — REF #101 BARBER-COLMAN #6-16, 6 Multi-Cycle REF#103 TOS OFA Series Conventional Gear Hobbers, 12” & 40” Dia REF#105 Phone: 330-425-4419 • Fax: 330-425-8600 G&E #36H Differential, Excellent Condition REF#103 TOS OHA Series Conventional Gear Shapers, 12” & 40” Dia REF#105 Email: [email protected] BARBER-COLMAN #14-30, 14” Dia, 30” Face, 3.5DP REF#103 TOS FO-16 with single index 72” cap. REF#106 Website: www.mwgear.com BARBER-COLMAN #14-15, 14” Dia, 15” Face, 1 to 4 Start Worm, Several REF#103 BARBER-COLMAN #16-16, 16” Dia, 16” Face, 6DP REF#103 New England Gear — REF #102 BARBER-COLMAN #16-36, 24” Dia, C-Frame Style, 4 1/8” Bore REF#103 GEAR PINION HOBBERS & SPLINE MILLERS Phone: 860-223-7778 • Fax: 860-223-7776 BARBER-COLMAN #16-56, 16” Dia, 56” Face, Differential REF#103 Email: [email protected] G&E #24H Universal Head, Infeed, Tailstock, Differential, ‘50’s REF#103 HURTH #KF-32A 15” Dia, 59” Face, ‘67 REF#103 Website: www.newenglandgear.com LIEBHERR #L-650, 26" Dia Cap, 14.5" Face, 2.5 DP, New ‘70’s REF#103 GE/Fitchuburg Pinion Hob 32” Dia, 72” Face REF#103 G&E #16H Gear Hobber, 16"Dia REF#103 MICHIGAN Tool #3237 REF#103 R. P. Machine Enterprises, Inc. — REF #103 BARBER-COLMAN #6-10, 6” Dia, 10” Face, 16 DP REF#103 FITCHBURG Pinion Hobber 42” Dia, 72” Dia REF#103 Phone: 704-872-8888 • Fax: 704-872-5777 KOEPFER #140 , 2.75” DIa, 4” Face REF#103 Craven horizontal 36” dia 96” length 73/4” hole REF#106 Email: [email protected] LANSING #GH-50, 50” Dia, 17.75” Face, 2 DP REF#103 LIEBHERR #L-252, 9.8” Dia, 7.9” Face, 4.2 DP REF#103 Website: www.rpmachine.com BARBER-COLMAN TYPE T REF#103 GEAR HOB & CUTTER SHARPENERS (incl CNC) Repair Parts, Inc. — REF #104 G&E #36HS 36”Dia, 14” Face 3 DP REF#103 PFAUTER #P-3000, 120” Dia, Single Index REF#103 BARBER-COLMAN #6-5, 6" Dia, 5" Length, Manual Dresser, ‘57 REF#103 Phone: 815-968-4499 • Fax: 815-968-4694 SCHIESS RFW-10-S 55” Dia REF#103 FELLOWS #6SB, Helical Cutter Sharpener, 6” Dia, up to 50 Degrees REF#103 Email: [email protected] SCHIESS 1 RF-10, Dia 60” 150” L, .50 DP REF#103 KAPP #AS-305GT, 1 DP, 28" Grind Length, 10" Diam., Str. & Spiral REF#103 Website: www.repair-parts-inc.com G&E #40TWG, 48” Dia, 18” Face, 3 DP REF#103 KAPP #AS204GT, 10” Dia, Wet Grinding, CBN Wheels, ‘82 REF#103 G&E #60S, 72” Dia, 14” Face, 1.25 DP REF#103 REDRING MODEL #SGH "PREIFORM" SHAVE CUTTER GRINDER/SHARPENER REF#103 Havlik International Machinery, Inc. — REF #105 G&E #72H, 72” Dia, 24” Face, 1 DP REF#103 STAR 6X8 HOB SHARPENER PRECISION GEAR & SPLINE HOBBER REF#103 Phone: 519-624-2100 • Fax: 519-624-6994 G&E #96H, 104” Dia, .50 Face, 1.25 DP REF#103 BARBER-COLMAN 2-2 1/2 , 2.5” Dia REF#103 Email: [email protected] PFAUTER #P-630, 25” Dia REF#103 KAPP #AST-305B, 27.5” Dia, REF#103 Website: www.havlikinternational.com PFAUTER P250 10” Dia REF#103 KAPP AS-410B REF#103 GE/Fitchburg Hobber 32” Dia, 72” Face 1.25DP REF#103 GLEASON #12 Sharpener, 3-18” Cone REF#103 GQ Machinery Inc. — REF #106 JF Reinecker 40” Dia 35” Face REF#103 Red Ring Shaving Cutter sharpener Periform REF#103 Phone: 516-867-4040 • Fax: 516-223-1195 LIEBHERR L-160-R 6.5” Dia REF#103 Star #6 Gear Cutter Sharpener REF#103 Email: [email protected] MIKRON #102.04 , 4’ Dia, 5” Face REF#103 Star 4HS Hob sharpener REF#103 Website: www.gqmachinery.com PFAUTER P-900 36” Dia REF#103 Star HHS Horizontal Hob Sharpener CNC, Max Dia 10” Max length 12” New 1990 REF#103 BARBER-COLMAN #25-15 25” Dia, 15” Face, 2.5 DP REF#103 BARBER-COLMAN 2 1/2-2, S/N 16, ’66 Wet w/Auto Feed REF#104 Gibbs Machinery Company — REF #107 PFAUTER #P-630R, 25" Max. Spur Dia, 12" Max Rotor Dia. 12" REF#103 BARBER-COLMAN 6-5, S/N 110R, ’55 Wet w/Auto Dress & Sparkout REF#104 BARBER-COLMAN 2 1/2 -4, S/N 119, ’62 Hi-Production Spur Gear REF#104 BARBER-COLMAN 6-5, S/N 396, ’66 Wet w/Auto Dress & Sparkout REF#104 Phone: 586-755-5353 Fax: 586-755-0304 BARBER-COLMAN 6-10 SYKES, Triple Thrd w/Lever Operated Collet Assy REF#104 BARBER-COLMAN 6-5, S/N 433, ’69 Wet w/Auto Dress & Sparkout REF#104 Email: [email protected] BARBER-COLMAN 6-10 B&C Ltd, S/N 8079, Triple Thrd REF#104 BARBER-COLMAN 10-12, S/N 643R83, Wet w/Auto Dress, PC Control, Fact Reb ‘83 REF#104 Website: www.gibbsmachinery.com BARBER-COLMAN 6-10, S/N 4626, ’57 Triple Thrd 3” Hob Slide REF#104 TOS OHA Series CNC Gear Shapers, 12” & 40” Diameter REF#105 BARBER-COLMAN 6-10, S/N 4659R, ’56 Triple Thrd Adj Ctr Assy REF#104 TOS OFA Series CNC Gear Hobbers, 12” & 40” Diameter REF#105 BARBER-COLMAN 6-10, S/N 4665, ’57 Fine Pitch Prec Triple Thrd REF#104 BARBER-COLMAN 6-10, S/N 4701, ’58 Triple Thrd w/Power Down Feed REF#104 GEAR ACCESSORIES, PARTS & TOOLING BARBER-COLMAN 6-10 M/C, S/N 4755, ’59 Triple Thrd w/MC Conversion REF#104 GEAR SHAPERS CNC FELLOWS Model #10-4/10-2, All Parts Available REF#102 BARBER-COLMAN 6-10 Multicycle, S/N 4778R87, ’60 (’87 Rebuild), Sgl Thrd Hi-Spd REF#104 36” Shapers, 14” Throat Risers, 53” of Swing, Qty 3 REF#102 Tilt Tables for 10-2/10-4, Qty 2 REF#102 BARBER-COLMAN 6-10 M/C, S/N 4913, ’63 Triple Thrd w/90 Deg Hob Slide REF#104 FELLOWS #10-4/10-2, Qty 150 REF#102 FELLOWS Parts Available For All Models REF#103 BARBER-COLMAN 6-10 Multicycle, S/N 5055, ’66 Triple Thrd, 800 RPM REF#104 HYDROSTROKE #50-8, Qty 2 REF#102 BARBER-COLMAN – PARTS AVAILABLE FOR ALL MODELS REF#103 BARBER-COLMAN 6-10, S/N 5141, ’67 Triple Thrd w/Prec Hob Shift REF#104 HYDROSTROKE #20-8, Qty 5 REF#102 G&E – PARTS AVAILABLE FOR ALL MODELS REF#103 BARBER-COLMAN 6-10 Multicycle, S/N 5148, ’68 Triple Thrd, 800 RPM REF#104 HYDROSTROKE #FS630-125, Qty 1 REF#102 BARBER-COLMAN 6-10 Multicycle, S/N 5259, ’75 Triple Thrd w/Auto HYDROSTROKE #FS400-90, Qty 2 REF#102 Hob Shift REF#104 FELLOWS #20-4, Qty 6 REF#102 GEAR HOBBERS/CUTTERS CNC BARBER-COLMAN 6-10, S/N 5353, ’77 Triple Thrd w/3” Hob Slide, FELLOWS #48-8Z, Qty 1 REF#102 PFAUTER #PE-150, 6-Axis CNC, 6” Dia, 5 DP, 6” Face, Fanuc 18MI REF#103 800 RPM REF#104 FELLOWS #FS-180, 3-5 Axis, 7” Dia, 1.25” Face., 6 DP, New ‘88 REF#103 G&E #60 S-2 CNC Gasher/Hobber REF#103 BARBER-COLMAN 6-10, S/N 5394, ’81 Fine Pitch Triple Thrd w/Dwell LIEBHERR #WS-1, 4-Axis CNC, 8" OD, 2" Stroke, Fanuc 18MI REF#103 BARBER-COLMAN #16-36, 16” Dia, 4-Axis, 6 DP, 36” Face REF#103 & Hob Rev REF#104 LORENZ # LS-180, 4-Axis CNC, 11” OD, 2” Stroke, 5 DP REF#103 MUIR CNC Gear Hobber, 4-Axis, 118” Dia REF#103 BARBER-COLMAN 6-16 M/C, S/N 5238, ’70 Triple Thrd, Recon ‘02 REF#104 LORENZ #LS-304 CNC Gear Shaper 5-Axis Heckler & Koch Control REF#103 LIEBHERR #L-252 3-Axis, 9.8” Dia, recontrolled 2008 REF#103 BARBER-COLMAN 6-10, S/N 5407, ’82 Auto w/PLC Control REF#104 FELLOWS FS400-125, 16” Dia, 3.5 DP 5” Face REF#103 LIEBHERR #ET-1802 CNC – 98” Dia Internal, 3-Axis REF#103 BARBER-COLMAN DHM, S/N 105, ’42 Double Thrd REF#104 FELLOWS #10-4 3-Axis (A/B), 10" Dia, 4" Face, 4 DP New .’09 REF#103 G&E #120GH, CNC, Gasher/Hobber, Twin Stanchion, 1/2 DP, 42” Face, ‘94 REF#103 BARBER-COLMAN 14-15, S/N 635R, ’53 Dbl Thrd, Fact Reb REF#104 FELLOWS #10-4 2-Axis, 10” Dia 4” Face REF#103 PFAUTER P400H, 5-Axis, 18” Dia, 1 DP, Recontrolled ‘03 REF#103 BARBER-COLMAN 14-15, S/N 745, ’55 Dbl Thrd w/Dwell REF#104 FELLOWS #20-4 3-Axis 10” Dia, 4” Face REF#103 G&E #96GH, CNC, Gasher/Hobber, New ‘09 REF#103 BARBER-COLMAN 14-15 Dual Fd, S/N 938, ’62 Dbl Thrd, Comp Reco REF#104 FELLOWS FS400-90 Hydro-stroke Gear Shaper CNC Nominal Pitch 15.7" REF#103 PFAUTER PE 300 AW CNC 6-Axis REF#103 BARBER-COLMAN 14-15, S/N 1055, ’65 Dbl Thrd w/New Hyd Sys REF#104 Fellows 20-8, CNC Gear Shaper, Remanufactured and recontrolled REF#103 Pfauter PE150, 15MB Fanuc, Chip Conveyor, Auto Load REF#107 BARBER-COLMAN 14-15, S/N 1131, ’66 Dbl Thrd w/Hyd Tailctr REF#104 Fellows Model Z gear Shaper REF#103 Pfauter PE150, Siemens 3M, Magnetic Chip Conveyor, Oil Chiller REF#107 BARBER-COLMAN 14-15 Dual Fd, S/N 1261, ’67 Dbl Thrd w/Hyd Live Ctr REF#104 Lorenz SN4 Gear Shaper, Max OD 7”, 2” Face, Max 6 DP with Loader REF#103 Pfauter PE150, Fanuc 15, with light hob slide 8” REF#107 BARBER-COLMAN 14-15 Dbl Cut, S/N 1278, ’68 Dbl Thrd w/4-1/8” Bore REF#104 RP/ Stanko 48-8 Remanufactured Gear Shaper, Fanuc 3 Axis, 18i M Control, new 2010 Pfauter PE80, 15MB Control, Auto Load, Light Curtain REF#107 BARBER-COLMAN 14-30 Dual Fd, S/N 1371, ’71 4-Thrd w/Sizing Cycle REF#104 REF#103 Liebherr LC82 15M Fanuc Control, Auto Load REF#107 BARBER-COLMAN 22-15, S/N 923, ’62 Dbl Thrd, Dbl Cut REF#104 BARBER-COLMAN 16-11, S/N 184, ’50 Dbl Thrd w/Vert DRO REF#104 BARBER-COLMAN AHM, S/N 1896, ’42 Sgl Thrd w/3 Jaw Chuck REF#104 GEAR HOBBERS GEAR HOBBERS/CUTTERS BARBER-COLMAN 16-16, S/N 2745, ’51 Sgl Thrd w/90 Deg Hd REF#104 PFAUTER P1251 Hobbers s/n 25-276 and 25-277 REF#102 BARBER-COLMAN 16-16, S/N 3171, ’53 Dbl Thrd, Spanish Nameplates REF#104 Barber Colman Model 4-4HRS, Hob Sharpener 4” Max OD, 4” Length REF#103 PFAUTER (1) RS-00 s/n 17593 REF#102 BARBER-COLMAN 16-16, S/N 3580, ’59 Dbl Thrd w/Diff & Auto Hobshift REF#104 Fellows FH 200 Gear hobber, universal hobbing Machine REF#103 BARBER COLEMAN (1) 16-36 multi cycle s/n 4404 REF#102 BARBER-COLMAN 16-16 Multicycle, S/N 3641, ’60 Dbl Thrd w/Diff REF#104 Barber Colman 6-10, CNC, CRt 5 Axis, 6” Dia, 10.5” travel, 6 DP REF#103

82 gearsolutions.com Barber Colman Hobber Type T REF#103 FELLOWS #36-6 Max Dia 36” 6” Face, 3 DP REF#103 GEAR GRINDERS Barber Colman model #14-15 Gear Hobber, horizontal Heavy Duty REF#103 FELLOWS #HORZ Z SHAPER, 10 x 6 Dia 27.6 Face 8.5” REF#103 #27, #137, and #463 Gleason Hypoid Spiral Bevel gear grinder Barber Colman Model #16-36 GearHobber REF#103 FELLOWS #4GS & 4AGS, 6” Dia, 2” Face, 4DP, ’68, Ref.# Several REF#103 generating Cams (2 full sets) REF#102 Barber Colman Model #16-56, 16” dia, 56” Face, adj. Air Tailstock REF#103 FELLOWS #624A, 18” Max Dia, 5” Face REF#103 Springfield Vertical Grinder, 62" Table, #62AR/2CS, 3.5A Rail Type, 70" Swing REF#102 Barber Colman Model 2.5-2 gear hobber, 2” length Manual Dresser REF#103 FELLOWS #7, #7A, #715,# 75A, #715, #725A, 7” Dia, 0-12” Risers, REISHAUER ZA, Gear Grinder, 13" Dia, 6" Face, Strait & Helix REF#103 G&E Model 5.2 CNC Internal Gear gashing head REF#103 Several Avail REF#103 GLEASON #463, 15” Dia REF#103 Jeil JDH-3, Gear hobber, Max Dia 31.5”, 3DP, 22.8 Table Diameter REF#103 MICHIGAN #18106 SHEAR-SPEED GEAR SHAPER,14" Dia, 6"Face REF#103 Hofler model Rapid 2000L, CNC Grinder, Max OD 78”, CNC Dressing REF#103 Jeil JDP-2, Gear hobber, Max Dia 26”, 4 DP, 19.5” Table Dia, Differential and tailstock FELLOWS Model Z Shaper, 5" Stroke, ‘50’s REF#103 Matrix model 78, Reman CNC Thread grinder, 24” Dia, 86” grind Length, 106 between REF#103 STAEHELY SHS-605, Gear Shaper REF#103 centers REF#103 Liebherr ET 1802, Internal Gashing head, Fanuc 16i Control, 98”Max dist 17” Face REF#103 FELLOWS #6, #6A, #61S, From 18”-35” Dia, 0-12” Risers REF#103 Mitsu Seiki Model GSW-1000 Gear Grinder REF#103 Liebherr L-402 Gear hobbing Machine, New 1977 REF#103 FELLOWS #8AGS Vertical Gear Shaper, 8” Dia, 2” Face, 6-7 DP REF#103 Reishauer RZ 362 AS, CNC Grinder, Max Dia 360mm REF#103 Liebherr LC 752, 6 Axis CNC Hobber, Max OD 29.5”, Max Face width 23.6” REF#103 TOS OHA50 CNC 5 20” Dia 5” Face REF#105 Sundstrand/Arter Model D12 Grinder REF#103 Micron Model 120.01 w/bevel Cutting Attachment, New 1975, 1.6” dia, 25.4 DP REF#103 Fellows 36-6 Shaper (2) 12.5" Risers 6" Stroke Mint YR 1969 id 3616 REF#106 Teledyne-Landis Gear Roll Finishing Machine, 5” Diam, 42k lbs Rolling Force REF#103 Nihon Kakai Model NTM-3000, Spline Hobbing Machine, Max dia 400mm, 3150mm between Fellows 36-6, shaper W/6” riser, change gears REF#106 Reishauer RZ301AS CNC, 13” Measuring System (3) REF#107 Center REF#103 Magg shaper SH4580-500S, 206”dia. 26” face REF#106 Reishauer ZB, 27.5” PD Gears, Coolant REF#107 Pfauter P900 Reman and Recontrolled, Max OD 120” REF#103 Magg shaper SH250, 98” dia. 26” face REF#106 Pfauter Model PE125 CNC Gear hobber REF#103 Fellows #10-4,7” riser yr 1980 REF#106 Pfauter model PE300 CNC, Max OD 12”, Max gear face 15”, 3 DP, 6 Axis Fellows 3”, 6”, 7”, 10”, 18”, 42”, 100, Some CNC REF#103 REF#107 GEAR RACK MILLERS/SHAPERS Reinecker Heavy Duty Gear Hobber REF#103 MIKRON #134 Rack Shaper, 17.4" Length, 1.1" Width, 16.9 DP REF#103 Scheiss Model RF10 Horizontal Hobber, 60” dia, 144” face, 180”cc, 8 DP REF#103 SYKES VR-72 Vert Rack Shaper, 72" Cut Length, 4DP, 4" Stroke, ‘80 REF#103 G&E 96H, roughing & finishing 104” dia. REF#106 GEAR DEBURRING/CHAMFERING/POINTING Fellows 4 – 60 Rapid Traverse, 2 Cut REF#107 TOS FO-16 single index 80” dia. Yr 1980 REF#106 CROSS #50 Gear Tooth Chamferer, 18” Dia, Single Spindle REF#103 Craven spline & pinion hobber 36” x 96” REF#106 REDIN #20D, 20” Dia, Twin Spindle, Deburrer/Chamfer REF#103 G & E 48H 48” dia. Diff, OB, change gears REF#106 SAMPUTENSILI #SCT-3, Chamf/Deburrer, 14” Dia, 5” Face, ‘82 REF#103 GEAR THREAD & WORM, MILLERS/GRINDERS Pfauter hobber P-1800 70” dia. 29” face yr 1980 REF#106 SAMPUTENSILI #SM2TA Gear Chamfering Mach, 10” Max Dia, (3) New ‘96 REF#103 BARBER-COLMAN #10-40, 10" Dia., 40" Length, 4 DP REF#103 Lees Bradner 7VH, 8”PD, 10” Face, , Magnetic Chip Conveyor , Hob Shift REF#107 REDIN #24 CNC Dia 4” Setup Gear Deburring REF#103 EXCELLO #31L, External Thread Grinder, 5" OD, 20" Grind Length REF#103 Lees Bradner 7VH, 8”PD, 4PD, Magnetic Chip Conveyor, Hob Shift REF#107 CROSS #60 Gear Tooth Chamferer, 10” Dia, Single Spindle REF#103 EXCELLO #33 Thread Grinder 6” Dia 18” Length REF#103 Mitsubishi Model GH300, 15.7”, 3 DP, Differential, 2 Cut REF#107 FELLOWS #100-180/60 CNC Max Dia 180”, Single Spindle REF#103 HURTH #KF-33A Multi-Purpose Auto-Milling Machine 88” REF#103 Tos 32A, 320mm Gear Dia.,3.6 DP, Differential, 2 Cut REF#107 CIMTEC #50 Finisher REF#103 LEES BRADNER #HT12x102, Extra Large Capacity REF#103 Gleason 775 8”PD, High Helix Head, Infeed, Very Light Use REF#107 CROSS #54 Gear Deburrer, 30” Dia, 18” Face REF#103 LEES BRADNER #HT 12"x 144" Thread Mill, 12" Dia, REF#103 Barber C. 16-15, 7 ½” Hob, Crowning, Differential, 2 Cut REF#107 RED RING #24 Twin Spindle Dia 4” REF#103 LEES BRADNER # LT 8” x 24” 8” Dia REF#103 Barber Colman 14-15, 2 Cut, Fast Approach, 4” Bore REF#107 GLEASON GTR-250 VG CNC 5-Axis REF#103 HOLROYD 5A 24.8 “ Dia REF#103 LEES BRADBER WORM MILLER REF#103 Barber Colman 16-36, Type A – Very Good, Double Thread Index REF#107 Gleason- Hurth Model ZEA 4, Max Dia 250mm, Max Module 5mm REF#103 Dranke CNC Internal Ball Nut Grinder REF#107 G & E Model 48HS 48”PD, 18” Face, 2.5 DP REF#107 Redin Model 36 universal Chamfering and Deburring Machine, Max OD 36”, Twin spindle, Tilt table REF#103 Samputensili SCT3 13.7”, SM2TA 10”, (5), 2003 REF#107 GEAR TESTERS/CHECKERS (incl CNC) GEAR SHAPERS Mitsubishi MA30 CNC, 11”PD, Fanuc, Powermate, 1999 (2) REF#107 FELLOWS (1) RL-600 Roll Tester s/n 35814 REF#102 FELLOWS #10-2, (10” Dia), 2” Face REF#102 FELLOWS (1) 24H Lead Checker s/n 32289 REF#102 FELLOWS #10-4, (10” Dia), 4” Face REF#102 GLEASON (1) #14 Tester s/n 31907 REF#102 GEAR HONERS FELLOWS (200) 10-4 / 10-2 Shapers REF#102 GLEASON (1) #6 Tester s/n 19316 REF#102 FELLOWS (1) 50-8 Hydrostroke Shaper s/n 36607 w/ Kapp #CX120 Coroning 4.7” Dia REF#103 FELLOWS (1) 20 M Roller Checker REF#102 6 axis 16iMB Fanuc (2009) REF#102 Red Ring GHD-12, 12” Dia, 5.5 Stroke REF#103 FELLOWS (1) 20 M w/ 30” Swing Roller Checker REF#102 FELLOWS (1) 20-8 Hydrostroke Shaper s/n 35932 w/ Red Ring GHG, 12” Dia, 5.5 Stroke REF#103 FELLOWS (1) #8 Micaodex s/n 36279 REF#102 6 axis 16iMB Fanuc (2009 REF#102 Kapp #VAC65 Coroning 10” Dia REF#103 David Brown #24 Worm Tester REF#103 FELLOWS (1) #7 125A Face Gear Machine REF#102 Gleason #4, #6, #13 and #17 Testers REF#103 FELLOWS (2) #3 Face Gear Machine REF#102 Hofler EMZ-2602 Int/Ext Gear Tester 102” REF#103 GEAR SHAVERS (1) 4ags with adjustable Helical Guide s/n 30634 REF#102 Klingelnberg #PFSU-1600 Gear Tester-2001 REF#103 (1) #7 125A adjustable Helical Guide REF#102 Red Ring #GCX-24" Shaver, 24” Dia, 33” Stroke REF#103 Kapp Hob Checker WM 410 REF#103 FELLOWS (1) FS630-200 Hydrostroke Shaper s/n 36943 w/ Red Ring #GCU-12, 12” Dia, 5” Stroke REF#103 Maag #ES-430 Gear Tester REF#103 6 axis 16iMB Fanuc (2009) REF#102 Red Ring #GCY-12, 12” Dia, 5” Stroke REF#103 Maag #SP-130 Lead and Involute Tester REF#103 FELLOWS (3) Tilt Table 10-4 / 10-2 w/ 4 axis 21i Fanuc Red Ring GCI 24, 12.75” Dia, 5” Stroke REF#103 National Broach Gear Tester GSJ-12 REF#103 Controller (2009) REF#102 Kanzaki model GSP 320 Gear shaver REF#103 Oerlikon #ST2-004 Soft Tester REF#103 FELLOWS (2) Swing-away center support for 10-2 / 10-4 REF#102 Red Ring GCU 12 Crowning, 1956 to 1988 (6) REF#107 Maag #SP-60- Electronic Tester REF#103 FELLOWS (1) FS630-170 Hydrostroke Shaper s/n 36732 w/ Mitsubishi FB30, 12.2 CNC Fanuc, 1997 REF#107 Parkson #42N Worm Gear Tester REF#103 6 axis 16iMB Fanuc (2009) REF#102 Sicmat Raso 100, CNC Fanuc 16M, New, Guarantee REF#107 Vinco Dividing Head Optical Inspection REF#103 FELLOWS (2) FS400-170 Hydrostroke Shaper w/ Gleason model 511 Hypoid tester Max Dia 20”, max spindle centerline 3.5” REF#103 6 axis 16iMB Fanuc (2009) REF#102 Klingelnberg Model PFSU-1600 63” Dia, 1.02 DP, Rebuilt REF#103 FELLOWS (4) FS400-125 Hydrostroke Shaper w/ 6 GEAR GENERATORS MAAG ES401 Pitch tester With Process Computer REF#103 axis 16iMB Fanuc (2009) REF#102 GLEASON #37 Str. Bevel Planer, 6” Dia REF#103 Fellows 12 & 24M Involute, 12 & 24 Lead REF#107 FELLOWS (1) 20-4 Shaper s/n 35687 w/ 4 axis GLEASON #496 Straight.& Spiral. 7.5” Dia REF#103 Fellows 36” Space Tester, Hot Pen Guaranteed REF#107 21i Fanuc Controller (2009) REF#102 GLEASON 725-Revacycle, 6” Dia REF#103 Gleason 17A Running or Rebuilt Guaranteed REF#107 FELLOWS (1) 48-8Z Shaper w/ 14” throated riser (53” of swing) REF#102 GLEASON 726-Revacycle, 5” Dia REF#103 Gleason 511, 20” Reconditioned in 2010 Guaranteed REF#107 FELLOWS (1) Horizontal Z Shaper s/n 21261 REF#102 Farrel Sykes Model 12C herringbone max dia 264”, max face width 60” REF#103 Gleason 27, 26”, Guaranteed REF#107 FELLOWS (1) 4-B Steering Sector Gear Shaper w/ 18iMB Farrel Model 5B herringbone gear generator. REF#103 Gleason 515, 24” REF#107 4 axis Fanuc controller s/n 34326 REF#102 Gleason 529 gear quench press, Auto cycle 16” Diam, New 1980 REF#103 Gleason 523, 20” Reconditioned, 2010 REF#107 FELLOWS (1) 36-10 Gear Shaper REF#102 Gleason 614 hypoid finishing machine, 10.5” pitch, dia 5.25” Max cone dist REF#103 FELLOWS (1) 10x6 Horizontal Z Shaper REF#102 Oerlikon/klingelnburg Model C28, Max dia 320 mm, Max Module 7.5 mm REF#103 FELLOWS (1) 36-6 Gear Shaper w/ 13” riser s/n 27364 REF#102 Gleason Model 26 Quench press and Hypoid Generator Max OD 16”, Max face Width Air Cylinder MISCELLANEOUS FELLOWS (1) 10-4 Shaper w/ 3” riser w/ 4 axis 21i REF#103 WARNER & SWAYSEY #4A M-3580 Turret Lathe, 28 1/4 Swing, 80” Centers, 12” Spindle Hole Fanuc Controller (2009) REF#102 Gleason Model 36 Gear Quenching Press, Max Ring 28” OD, 8” Face, Universal REF#103 50/25 Motors, 480/3 Phase, Year 1965 REF#101 All Parts for 10-4/10-2 Fellows Gear Shapers REF#102 Gleason Model 450 HC CNC Hypoid Cutter, Face width 2.6”, fanuc 150 Controls REF#103 Springfield Vertical Grinder, 62" Table, #62AR/2CS, 3.5A Rail Type, 70" Swing REF#102 FELLOWS #36-8, 36” Dia, 8” Face REF#103 Gleason 24 Rougher, Gears, Finishing Tool Holder REF#107 GLEASON #529 Quench, 16" Diameter REF#103 FELLOWS #100-8 100” Dia, 8” Face REF#103 12” Gleason, Gears, Gauges Tool Blocks REF#107 Klingelnberg Model LRK-631 Gear Lapper REF#103 FELLOWS #612A, 615A, #645A REF#103 Gleason 116 Rougher & Finisher (6) REF#107 VERTICAL TURNING LATHES AND MORE - Please Check Our FELLOWS #10-4, 10” Dia, 4” Face, 4 DP REF#103 Gleason Phoenix 175HC CNC – 1994 REF#107 Website To View Our Entire Inventory REF#103 FELLOWS #4A Versa, 10” Dia, 3” Face, 4 DP, New ‘70’s REF#103 Gleason 22 Rougher & Finisher (8) REF#107 TOS SU & SUS Series Conv Lathes REF#105 FELLOWS #10-2, 10” Dia, 4” Face, 4 DP REF#103 Gleason 610 Combination Rougher & Finisher, 1988 REF#107 TOS SUA Series CNC Flat-Bed Lathes REF#105 FELLOWS #20-4, 20” Dia, 4” Face, 4 DP, ‘70’s REF#103 Gleason 608 & 609 Rougher & Finisher REF#107 Change gears for G & E hobber REF#106 FELLOWS #3-1,/3GS, 3” Max Dia, 1” Face, Pinion Supp, High Precision REF#103 Gleason 7A, 7”PD Helical Motion, Gears & Cams REF#107 FELLOWS #48-6 INTERNAL GEAR SHAPER ONLY,0-72"OD,6" Face REF#103 Gleason Cutters, 3” to 25” in stock, 1000 REF#107 MAAG #SH-150, 57" Dia.12.6" Face REF#103 PFAUTER #SH-180 Shobber 7" capacity hobbing, 9.45" cap REF#103

SEPTEMBER 2014 83

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The Gear Motions Network: Nixon Gear | Oliver Gear | Pro-Gear | Niagara Gear ADVERTISER INDEX COMPANY NAME...... PAGE NO. ALD-Holcroft Vacuum Technologies...... 12 ALD Thermal Treatment Inc...... 75 All Metals & Forge Group...... 66 Allen Adams Shaper Services...... 85 Apollo Broach...... 85 Bourn & Koch...... 87 Brelie Gear Company...... 61 Brevini Gear...... 52 Broaching Technologies...... 79 C-B Gear & Machine Inc...... 84 Carmona Gear Cutting...... 85 Chamfermatic Inc...... 76 Circle Gear & Machine...... 87 CNC Machinery Sales Inc...... 54 Cosen Saws...... 48 Drewco...... 15 DT Technologies...... 36 Encoder Products...... 76 Engineered Tools Corporation...... 50-51 Erwin Junker Maschinenfabrik GmbH...... 16 Booth Forest City Gear...... IBC #N-6924 Gear Manufacturing Inc...... 49 Gear Motions...... 86 Gleason Corporation...... 59 GMTA (German Machine Tools of America)...... 2 Griffin Gear Inc...... 41 Havlik Gear...... 38-39 HobSource Inc...... 74 Hydra-Lock Corp...... 9 Index Technologies...... 85 Innovative Rack & Gear ...... 74 Invo Spline Inc...... 85 Ipsen International...... 37 KAPP Technologies...... IFC,42 KISSsoft USA LLC...... 36 CIRCLE GEAR and MACHINE Koro Sharpening Service...... 85 Lawler Gear Co...... 85 Liebherr...... 35 STRAIGHT BEVEL GEARS Lufkin Industries LLC...... 21 Luren Precision Co Ltd...... 43 .25” to 34 ½” Diameter Machine Tool Builders...... 78 McInnes Rolled Rings...... 11 32 DP to 1.5 DP Micro Gear...... 54 Micro Surface Corp...... 79 .5 Module to 16 Module Mitsubishi Heavy Industries America Inc...... BC Mitsubishi Materials USA...... 62 Mohawk Machinery Liquidators...... 69 National Bronze & Metals...... 65 New England Gear...... 7 P & G Machine & Supply...... 58 PentaGear Products...... 40 SPIRAL BEVEL GEARS Pinson Valley Heat Treating...... 41 Proto Manufacturing Ltd...... 13 .25” to 33” Diameter QC American...... 31 Raycar Gear & Machine Co...... 25 32 DP to 2 DP Reishauer Corporation...... 41,55 Repair Parts Inc...... 65 .5 Module to 12 Module Richardson Manufacturing Co...... 34 Rotek Inc...... 14 Since 1951 Circle Gear has served Roto-Flo...... 64 Chicago land as a full service gear RP Machine Enterprises Inc...... 80-81 manufacturing facility. In addition to bevel gears Circle Gear also Russell Holbrook & Henderson...... 60 provides spur gears, helical gears, Solar Atmospheres...... 67 herringbone gears, worm and gear STD Precision Gear...... 58 sets, internal gears, splines, racks The Broach Masters Inc...... 4 and sprockets. The Ohio Broach & Machine Co...... 10 Thermo-Calc Software Inc...... 63 TMFM LLC...... 68 Toolink Engineering Inc...... 1 Walker Forge...... 53 Weldon Solutions...... 44 Willman Industries Inc...... 70

SEPTEMBER 2014 87 Q&A Bruce Cox PRESIDENT BRUCE COX ENGINEERING CORPORATION

set up booths, but I mainly attend for the technical content, as well as the committee meetings. I’m on the NCSLI committee on dimensional metrology, so we had our meeting down there. So word of mouth is pretty much how I meet people. I’m also a member of the American Society of Precision Engineers, which includes a lot of technical meetings about dimensional metrology and dimensional measurement. I meet people on those committees as well. They come looking for me to do an assessment. It starts out small, but people find out about you and start asking for you. You have to make a decision: full time? part time? That’s where I am now. I’m at the point where I’ve just about got everything I can do. I don’t work as much during the wintertime, because GS: You provide assessments to I don’t want to go to the freezing Midwest in the middle of February. It’s not a pleasant ISO/IEC 17025 for calibration place to be, with all that snow! I try to minimize the travel during those times. Hawaii laboratories. How has business might be good, depending on what they have. been? BC: I do assessments now, that’s the GS: If I hear of any consulting work in Hawaii I’ll send it your way. main thing, for the National Voluntary BC: Yeah, let me know about that! Fortunately for me, August, September, and October Laboratory Accreditation Program is when most people want their work done. That’s when it’s nice out. (NVLAP), part of the National Institute of Standards and Technology (NIST). Things GS: What has changed in the nature of the need to be accredited as opposed are going good. I’m getting busy, going to 30 years ago? through the process of looking at different BC: The need has increased quite a bit. I was a little surprised at the L-A-B training a companies’ documentation and paperwork couple of years ago. Before I retired from Oak Ridge, I asked the teacher about the need to see if they meet the ISO17025 stan- for consulting work in accreditation assessment. He said it has grown 30 percent a year, dard. Another accrediting body, a pri- and I’m trying to to keep up with it. vate company, Laboratory Accreditation Bureau (L-A-B), sends me on assessments GS: What is the initial assessment like when you arrive? to ISO 17025. I’ve also starting to do con- BC: You’ll have a lead person there. Next time you’ll be the lead, have someone evaluate sulting work with companies getting ready you. It’s usually two steps: technical assessment with a lead person there doing the for their accreditation as well. Hopefully main assessment, while you’re just doing part of it. Next, you do the whole thing and we’ll get them ready, and they’ll apply and someone’s helping you. Some small companies use just one person doing the whole go through the process. thing. Most of the smaller companies use just one assessor. For bigger laboratories, like the Oak Ridge Metrology Center, the accrediting body might send two people for four GS: How do they find you? days to get the work done. It just depends on how big it is. BC: Word of mouth, really. As part of I’ve also recently gone through the training course that the American Association for the assessment business, I go out and try Laboratory Accreditation (A2LA) holds. They have more labs than most other people, to maintain my technical competence. since they are a larger organization. They want me to be involved in an assessment in I attend conferences like the National November. Conference of Standard Laboratories International—they just had a meeting GS: Do you get to do a lot of traveling? in Orlando last month. I was down there BC: I like to do some traveling, but it gets to the point where it’s more than I want to. meeting with people, and many of the At least at these conferences usually they’re pretty nice, better locations, like Hawaii. people I do business with were at this When I went down to Orlando I went and visited and did a “cousin tour” while we were meeting. You meet with people and they in Florida. I got another assessment coming up in West Virginia. I’m trying to plan for say, “Well, we need to be accredited. We the fall, where the leaves are peaking just right.” could use your help.” I have been talking with the same companies for several years, and they decided that they were losing TO LEARN MORE: business because they aren’t accredited. visit www.bcoxengineering.com or call 865-617-6906. The conferences have talks and companies

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