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Gear Resonance Analysis GEAR SOLUTIONS GEAR 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 IMTS Manufacturing SEPTEMBER 2014 SEPTEMBER 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 Growth Fund. 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 exter- nal grinding by swiveling the grinding arm 1800. Wheels are dressed while in grinding position. Precise, efficient, flexible. Booth #N-7036 See us on the web! kapp-usa.com 2870 Wilderness Place | Boulder, CO 80301 p: 303.447.1130 | f: 303.447.1131 | [email protected] The most interesting man in the gear world He once climbed the Matterhorn and attended a machine run off, in Germany, on the same afternoon He has been known to hand carry parts to his secret manufacturing plant, in an unknown location But, when it comes to workholding, He always prefers König Stay productive, my friends 1921 Miller Drive Longmont, CO 80501 303-776-6212 www.toolink-eng.com OUR LINE JUST GOT LONGER... Looking for a partner for your high-production, multi-station machining, assembly and finishing operations? German Machine Tools of America (GMTA)TA) now offers a broad assortment of vertical turningg lathes, lathes horizontal gear cutters, single and double-side grinding machines, the patented Scudding® process for gear internals, honing machinery and now, laser welding assembly and parts washing equipment. Our recent additions of the Arnold laser line and Rosink parts washers mean you have end-to-end expertise from just one phone call. We’re not all things to all people, but we’re getting there! Plus, you enjoy the advantages of GMTA application engineering, unmatched experience in the manufacturing technologies for gears and other power transmission components, multi-national support in sales and service, plus the unique assortment of machine tools and related equipment to keep your process at peak efficiency. Cut, clean and combine your power transmission and other part assemblies with GMTA on your team.. Call Scott Knoy at 734-973-7800 today See our machines in action! Gear and Spline with Scudding® VTL Power Honing Center Drive Turning Parts Washing Laser Welding See At Booth N-6670 4630 Freedom Drive | Ann Arbor, MI 48108 | 734-973-7800 | www.gmtamerica.com | Email: [email protected] 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 con- ducted 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.
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