Engineering Principles for Plastic Gears by Rudy Walter in Many Instances, Plastic Materials Perform Markedly Better Than Do Metals—Especially Pg
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Also:Also: AA SuperSuper ToolTool forfor SUPERIORSUPERIOR GEARGEAR BLANKSBLANKS MakingMaking “Cents”“Cents” ofof DIEDIE CASTING COMPANYCOMPANY PROFILE:PROFILE: RaycarRaycar GearGear && MachineMachine Co.Co. SAFETYSAFETY MATTERS:MATTERS: EmployeeEmployee InputInput is Crucial TOOTHTOOTH TIPS:TIPS: DeterminingDetermining thethe CauseCause ofof EquipmentEquipment FailureFailure QQ&&AA withwith ChrisChris VianVian // TheThe BroachBroach MastersMasters A MEDIA SOLUTIONS PUBLICATION OCTOBER 2004 CLARKE GEAR COMPANY The QUIET company with more Gear technology per square foot than you’ll find anywhere. #1 in Service. • CNC Gear Grinding • CNC Hob Sharpening • Serrations • Face Gears (AGMA CL.15) • CNC Gear & Hob Inspection • Sprockets • Internal & External • CNC Gear Cutting • CMM Inspection Service • Spur to 12” Diameter • CNC Machining • Crown Gears • Helical • AS 9100 • CNC Gear Analysis • Splines • Worms • ISO 9000 CLARKE ENGINEERING, INC. Since 1954 50Ye a r s PH: 323-877-7590 • 818-768-0690 • FAX: 818-767-5577 of 8058 LANKERSHIM BLVD. • N. HOLLYWOOD, CA 91605 GEARS EMAIL: [email protected] • WWW.CLARKEGEAR.COM Gear Up with Clarke TOLL FREE: 888-277-GEAR (888-277-4327) OCTOBER 2004 A MEDIA SOLUTIONS PUBLICATION 6 industryNEWS 11 andyMILBURN – Tooth Tips New products, trends and developments in the Think like a detective when it comes to gear-manufacturing industry. determining the cause of equipment failure, because it will pay off in the long run. 10 terryMcDonald – Safety Matters departments Since employees are on the front lines of the manufacturing process, their input is crucial— especially when it comes to safety concerns. www.gearsolutionsonline.com features 12 Company Profile – Raycar Gear & Machine Co. By Russ Willcutt Paying attention to details and growing in a methodical manner has allowed this com- pany to break from the pack and emerge as an American success story. pg. 16 16 Making “Cents” of Die Casting By Stuart Burke Cost savings, a streamlined production process, and increased quality are only a few of the reasons why die casting is an excellent alternative for manufacturing small gears. 24 Engineering Principles for Plastic Gears By Rudy Walter In many instances, plastic materials perform markedly better than do metals—especially pg. 24 in gears. Learn the details that will allow you to make the best choice for your operation. 36 A Supertool for Superior Gear Blanks pg. 36 By Fritz Greulich With benefits including no heat buildup or chip problems, rotary saw cutting has emerged as the premier process for producing quality gear blanks. 48 Q&A — Chris Vian A conversation with the Vice President of The Broach Masters, Inc. industry resources 41 MACHINES 44 MARKETPLACE 47 INDEX OF ADVERTISERS gearsolutionsonline.com • OCTOBER 2004 • GEAR SOLUTIONS 3 From the Managing Editor There are many different ways to approach what I consider to be the “art” of publishing magazines. I studied journalism in college, for instance, but my real education began after I’d graduated and was hired by my alma mater, where I spent six years first working in the media relations department and Tthen in the publications division. There I learned how to build a magazine from the ground up, launching publications about engineering, business, and Published by medicine, among others. Thanks to our many contributors my education Media Solutions, Inc. continues to this day, because with every issue of the magazine we produce, P. O. Box 1210 I gain a world of insight into this fascinating and ever-evolving industry. Pelham, AL 35124 As anyone who’s visited our Web site and downloaded our media kit knows, each issue of Gear Solutions is planned far in advance of its actual publica- 1-800-366-2185 tion. This serves a number of purposes. One is that it allows us to plot a map that will cover as much ground as possible over the course of a year. Another is David C. Cooper that, since we make our editorial calendar available to everyone, subscribers and PUBLISHER non-subscribers alike, we receive queries and submissions from a broad range of Chad Morrison potential contributors; many of whom haven’t—and perhaps never will—adver- VICE PRESIDENT tise in the magazine. We build this framework, but then we remain flexible with- in it, because our primary goal is to provide a level playing field on which every- Brad Whisenant one has the chance to present news of their latest discoveries and advancements NATIONAL SALES MANAGER for the benefit of our readers. While we don’t hold ourselves up as the authority on these subjects, we feel that we provide an important service: acting as a Teresa Hall conduit through which a wealth of valuable information can flow. OPERATIONS/ CIRCULATION One of the standing features that I enjoy producing the most is our Michele Hall “company profile,” in part because I see so many similarities to the way we A DMINISTRATIVE came into being ourselves. When I hear someone talking about how they A SSISTANT learned the business at their father’s knee, I recall how my own father has Lisa C. Harkins always told me to “work hard, be positive, and stay humble.” And when I A DMINISTRATIVE hear stories of companies who are now big names that began their opera- A SSISTANT tions in a garage or a basement, I remember that we started small, too. That’s an important point, and one that I think many of our readers PRODUCTION can relate to. Instead of inflating our salaries and buying fancy cars, we’re Andy Spain folding our revenues back into the product. We’re working to develop an ART DIRECTOR online forum in which your questions will be answered by industry experts, and even now our Web site provides connections to the very people you EDITORIAL might need to know about in order to achieve your own goals. In short, we don’t feel that we’ve “arrived” by any means, and we probably never will, Russ Willcutt because the minute you start thinking along those lines, you’re done learn- MANAGING EDITOR ing. And I, for one—and I think I can speak for all of my colleagues at Gear CONTRIBUTING WRITERS: Solutions—am a major fan of lifelong learning. Stuart Burke If you’re with me at this point, I’ll assume that you’ve read my letters Fritz Greulich in past issues and realize this is something of a departure from the usual. Terry McDonald I will return to the standard format in the future, however, because I feel Andy Milburn, P.E. that it’s important to thank the contributors who fill each issue of the Rudy Walter magazine. This letter is my chance to acknowledge and spotlight their efforts publicly, and I think there’s something to be said for that. One man does not a magazine make, after all. The views expressed by those not on the staff of 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 Russ Willcutt by the subject company or pulled directly from their corporate Managing Editor Web site, which is assumed to be Gear Solutions magazine cleared for release. Comments [email protected] and submissions are welcome, and can be submitted to (800) 366-2185 [email protected]. 4 GEAR SOLUTIONS • OCTOBER 2004 • gearsolutionsonline.com © 2004 Media Solutions, Inc. industryNEWSindustryNEWS New Products, Trends and Developments in the Gear-Manufacturing Industry Brown & Sharpe Announces New Products The new TESA® UPD Gage Block Comparators from Brown & Sharpe improve calibration accuracy and reduce the time required to calibrate a set of gage blocks by up to 75 percent. TESA UPD Gage Block Comparators can be used for both direct and comparative measure- ment of gage blocks. In the direct measurement mode, the nominal length of the gage blocks to be compared can vary up to 25 mm, approximately 1 inch. In the comparative measurement mode, gage blocks of the same nominal length can be checked. With the nine-piece TESA UPD set, users can check more than 90 percent of a 122-piece gage block set using the same reference gage block, reducing calibration time. The reference gage set can be reduced by nearly 80 percent when compared with traditional gage block com- parators, with resulting lower gage block supply and calibration costs. Single or dual template systems provide optimum gage block handling. The new dual template system provides maximum protection for refer- ence gages since the master set can be left in the park position until needed. The dual template system also reduces the travel distance of the master gage by nearly 70 percent, reducing the risk of damage during the measuring process. With the single template system, the reference gage and the gage block move together during measurement cycles. TESA UPD Gage Block Comparators are equipped with Heidenhain high precision incremental probes. They can be equipped with a temper- Brown & Sharpe’s new TESA® UPD Gage Block Comparitor ature acquisition device that captures the temperature of the two gage blocks, the measuring table and support. TESA UP software processes scanning modes improve scanning accuracy and throughput by optimiz- length and temperature values as measured and controls the measure- ing 3D vector path control for parts with a changing rate of curvature. ment cycle. It makes all relevant corrections automatically, accounting The result is a smooth, continuous probe path that increases for actual length of the reference gage blocks, flattening compensation, machine throughput by an additional 30 percent. and temperature variations. Output results are in accordance to ISO The REFERENCE CMM features an all-aluminum ultra-rigid frame 3650. This advanced software is menu driven by and works with with a heavy, stable granite table to resist vibrations.