Engineering Principles for Plastic Gears by Rudy Walter in Many Instances, Plastic Materials Perform Markedly Better Than Do Metals—Especially Pg

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: Employee Employee 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 company 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 within 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 measurement 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 comparators, 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 reference 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. Tricision(tm) Windows 95 or later, Windows NT and ME. It is available with preset bridge design orients the bridge for optimum stiffness-to-mass ratio. gage set compositions. For more information on this product contact Dovetail guideway construction with wrap-around air bearings Lee Kirtlink at (401) 886-2000 or [email protected]. improves accuracy and repeatability. An automatic linear thermal com- In addition, the REFERENCE coordinate measuring machine available pensation system consisting of sensors installed in each axis scale from Brown & Sharpe is a high accuracy, high performance scanning allows the REFERENCE to adapt to ambient thermal conditions. It is machine that offers advanced dimensional data gathering and analysis suitable for all high accuracy applications such as turbine blades, capabilities. gears, and screw and scroll compressors. Long probe extensions and The REFERENCE CMM uses advanced Leitz Scanning Probe (LSP) sophisticated engine valve analysis software make this CMM an opti- technology for high speed scanning of geometric shapes and free mum measuring solution for automotive power train applications. form surfaces. LSP technology combines and optimizes all facets of The REFERENCE CMM can be equipped with QUINDOS(r) or PC- the probing process including automatic probe weight compensation, DMIS(r) measurement and inspection software. Options include an auto- advanced motion controller firmware, and advanced filtering algo- matic probe changer, rotary table, and interface to accommodate manu- rithms to support high-speed, high-accuracy open and closed loop al and automatic part loading systems. To learn more about this product scanning applications. This advanced LSP technology facilitates both contact Peter Edge at (401) 886-2000 or [email protected]. high speed scanning of known and unknown contours and the advan- For comprehensive information call Gail H. Wagner—account tage of measuring with very long probe extensions. executive with the RDW Group, Inc.—at (401) 521-2700. Brown & The control system incorporates continuous axes motion interpolation, Sharpe’s direct number is (800) 766-4673, and its Web address is integrating axes movements by eliminating stops and corners. Adaptive [www.brownandsharpe.com].

6 GEAR SOLUTIONS • OCTOBER 2004 • gearsolutionsonline.com Danaher Announces New Motor Mounting System In a recent press release Danaher Motion introduced the Micron Gearhead RediMount™ Motor Mounting System. The system features a simple three-step mounting procedure that allows all Micron gearheads to be mounted to any available motor, regardless of manufacturer. This flexible system also facilitates fast and easy changeover to alternate motors in the field. “The unique RediMount design allows our gearheads to be easily mounted to any motor,” according to Howard Horn, product manager. “The easy-to-use system features a specially designed input housing and sleeve to accommodate all motor mounting dimensions.” The mounting system has a self-aligning hub that maintains concentricity between the motor shaft and gearhead, while a pre-installed pinion eliminates normal pinion setting procedures. The unit’s modular design allows customers to stock gearhead and RediMount Micron Gearhead RediMount™ Motor Mounting System from Danaher units separately. Danaher Motion is a leading global manufacturer of motion control products that improve the efficiency and productivity of complex manu- New Metrology Interface from Precision Gage & Tool facturing operations. The company’s product innovations have been rev- Precision Gage & Tool Company has introduced the new P-400 DRO olutionizing the motion control industry for over 60 years through trust- Metrology Interface, an advanced multifunction gaging terminal that is ed brand names including Dover Kollmorgen, MEI, Pacific Scientific, ideal for air/electronic and electronic gaging systems. Offering intu- Portescap, and Thomson. Danaher Motion is a strategic business plat- itive visual displays, the P-400 can apply mathematical formulas to form of the Danaher Corporation, a manufacturer of process and envi- measurement data from up to 16 output channels for on-the-spot ronmental controls, tools, and industrial components. analysis. It offers SPC analysis from an integrated database, dynamic For more information call (866) 993-2624 or send e-mail to contactus min/max measurement reporting, and connectivity to PCs and other @danahermotion.com. Visit online at [www.danahermotion.com]. peripherals. Combined with an air/electronic converter and air gage

The finest quality RUSSELL, TRU-VOLUTETRU-VOLUTE HOLBROOK & A Leader in the Gear Tool Business for over 50 Years. HENDERSON, INC. 17-17 Route 208 North, Fair Lawn, New Jersey 07410 Telephone: 201-796-5445 Fax: 201-796-5664 A MEMBER OF OGASAWARA GROUP

Master Gears Ultra Precise Hobs HOB Resharpening Service Accuracy Class: AAA, AA, A Materials: Carbide/Bridge/HSS Technology: Dry/High Speed/ Shaper Cutters Hard Hobbing Range: 10~500 Diametral Pitch STOCK AVAILABLE Gear Rolling Tester

TRU-VOLUTE HOBS CNC HOB Sharpening Machine Visit our website at: http://www.tru-volute.com

gearsolutionsonline.com • OCTOBER 2004 • GEAR SOLUTIONS 7 grated RS-232 connectivity; other external stock. In view of the fact that this line is com- connections include a parallel port, remote prised of 57 combinations of ground tooth keypad, and footswitch. spiral bevel gears, which can be modified to Precision Gage & Tool maintains a leader- fit customer applications, Arrow Gear is posi- ship position in the engineering and manu- tioned as the only manufacturer in the world facture of high-accuracy Sheffield air and to offer such a product line. The availability of electronic gages as well as dial indicator these products promise to assist manufactur- and functional gages for the metalworking ers of power transmission systems with a low and manufacturing industries. Fineness of cost solution for prototype development and grind gages and film applicators are sup- low volume production. Key benefits of plied to the ink and paint industries world- Arrow’s stock gear product line include: wide. Precision Gage & Tool also produces specialized gages for railroads. • Cost savings of more than 50 percent To learn more call (937) 866-9666 or send e- • Delivery in days, not several months P-400 DRO Metrology Interface from mail to [email protected]. The company’s Web • Contact pattern can be modified to meet Precision Gage & Tool site is [www.pgtgage.com]. customer gearbox deflection requirements • Up to 16 inches in diameter tooling or LVDTs, the P-400 is a high-accuracy, economical gaging instrument ideal for appli- Arrow Gear Now Stocking As an alternative to custom gears—which cations requiring up to eight discrete inputs. Complete Line of Ground Tooth can cost tens of thousands of dollars to Operators get visual feedback from an design, develop, and produce—Arrow’s easy-to-read, familiar interface with standard Spiral Bevel Gears stock gear line provides dramatic cost sav- color cues and a choice of graphical formats. In a recent press release Arrow Gear ings for designers of power transmission The P-400 instantly reports pass/fail perform- Company—a global provider of high precision systems. And to offer additional production ance details for critical part dimensions and gearing that is based in Downers Grove, flexibility, Arrow’s engineers are available to can store, retrieve, and manage measure- Illinois—announced that it now offers a full assist in the modification of stock gears to ment data on the shop floor. It features inte- line of ground tooth spiral bevel gears from match the customer’s specific requirements.

8 GEAR SOLUTIONS • OCTOBER 2004 • gearsolutionsonline.com “Our stock gear product line is unique for several reasons,” accord- and even make catalog offers in a cost-effective format,” says ing to James J. Cervinka, the company’s CEO and chairman of the Cooper. “This deck will be sent to a wide variety of markets: from board. “First, no one else in the world offers stock ground tooth spiral aerospace to automotive, and from durable goods manufacturing all bevel gears in the variety that we do. Secondly, our engineers are avail- the way through primary metals, with more than 200,000 distributed able to assist with modifications to the contact pattern and other physi- annually. We’re excited about this project, and I think it will be of cal attributes to meet the customer’s specific requirements. Finally, by great benefit to the manufacturing industry.” using our stock gears, customers can save a great deal of expense. In To learn more, or to make sure that you receive the new Machine view of the brutal global competition that many companies are now fac- Shop Solutions Card Deck, call Jimmie Brasher, national sales ing, we feel that our product line of stock gears can serve as a power- manager, at (800) 366-2185 or send e-mail to either ful resource for a manufacturer’s competitive posture.” [email protected] or [email protected]. Founded by Cervinka in 1947, Arrow Gear provides a wide variety The dedicated Web site is [www.machineshopsolutions.com]. of loose gearing and complete gearboxes for commercial and aerospace customers. Currently, Arrow Gear produces more loose gearing for jet engine applications than any other gear company in the world. Brushless DC-Powered For more information contact Bob Wasilewski, design engineering Gear Motor from Merkle-Korff manager, at (630) 969-7640 ext. 255 or send e-mail to rfwasilewski The new Gf-bdlc gear motor by Merkle-Korff Industries offers @arrowgear.com. The company’s Web site is [www.arrowgear.com]. extended life, high efficiency, brushless technology, and provides up to 300 in/lb. or output torque over a variable speed range of one to 30 rpm. The heavy duty GF gearbox has been combined Media Solutions Introduces with a 2.25” double ball bearing brushless motor which features Machine Shop Solutions Card Deck ultra-quiet operation and provides all the benefits of brush-type On October 1, Media Solutions, Inc.—which produces Gear Solutions motors without the limitations of brushes and commutators. magazine—issued the Machine Shop Solutions Card Deck. The deck Optional features include customized output shafts, integral con- will be of great value to those who receive it for a number of reasons, trols, programmable dynamic braking for brake-drive resistance, according to David C. Cooper, president of Media Solutions. various mounting options, and custom speed profiles. “This is a great way for our clients to build a mailing list, find dis- For more information call Jim Van Huis at (847) 296-8800. The tributors, launch products, maximize their exposure, generate leads, company’s Web site is [www.merkle-korff.com].

Custom Manufacturing of High Performance Gears

Spur and Helical Gears up to 10" diameter Shaping, Hobbing & Gear Grinding Palloid, Spiral Bevel & Hypoid Gearing Gear Assemblies Custom Machining Testing & Inspection O.D. / I.D. Grinding

HIGH PERFORMANCE GEAR, INC. 2119 FM 1626 • Manchaca,TX 78652 Ph: 512-292-9148 • Fax: 512-280-0678 • Email: [email protected] • www.hpgear.net

gearsolutionsonline.com • OCTOBER 2004 • GEAR SOLUTIONS 9 terryMcDONALDterryMcDONALD Member of the ANSI Subcommittee on Gear Safety SAFETY MATTERS Since employees are on the front lines of the manufacturing process, their input is crucial—especially when it comes to safety concerns.

m I going to get in trouble if I point you follow up on the hazard and report back consists of changing blades when they are out what I think is an unsafe prac- to the original presenter on the progress? Do dull and only doing repairs as necessary. “A tice? If you are like me and came up you make sure that the report is included in Saws can be a very dangerous tool, and the through the ranks, so to speak, you probably that person’s personnel file? Do you do all of guards are too often taken off because remember when you had thoughts like this. Is these things in a timely manner? If we do not “they are in the way” or because “I didn’t it possible that your fellow employees have do all of these things and more, we are not have time to put them back.” Due to the fact the same concerns when they see something representing the best interest of our company, that this is sometimes considered a second- that troubles them? I think that this attitude is and we are allowing a potentially disastrous ary operation, often the saws are off in a still prevalent in the workplace. We must con- vey the message to all of our employees that situation to continue to exist. back room or a corner of the shop that is it is in the best interest of the whole compa- Please, once only visited when ny—which, of course, includes them—to bring you’ve convinced someone needs any and all safety concerns to the attention of your employees “Once you’ve convinced your them. This their supervisor. They need to be assured that that you value means that an they will not be chastised or thought less of, their input, fol- employees that you value their input, operator is often and that they will actually be appreciated for low up on their follow up on their concerns. It’s alone in the saw their contributions. concerns. It’s one of the most important things area, and if they I believe that many employees are really con- one of the most experience a cerned that supervisors will see their concerns important things we can do to improve safety in problem, there is as a way of getting out of a job or, even worse, we can do to the workplace.” no one there to that they are slowing down production. They improve safety help. We need to think that they may be considered to be spend- in the workplace. address this ing too much time looking for problems instead One of the topics in this month’s issue of issue and make the saw operation a safer of doing the job they were hired for. We need Gear Solutions is saws. We all use saws in part of our overall shop practices. their input to have the safest possible work- our business—some to prepare blanks, and Did everyone enjoy the various benefits place. We can’t expect to find all of the poten- some to finish parts—and I am sure that of IMTS? I hope you had the opportunity tial hazards that exist without input from all of there are any number of ways that they are to attend, and I plan to discuss what I our employees. I don’t mean to say that the used. Many times the saws are treated as observed from a safety standpoint in next employees should be expected to find all of the merely a secondary tool, and maintenance month’s column. hazards, or that the reports of hazards from employees should be anything but presented in the best interest of the company. Anyone in a ABOUT THE AUTHOR: supervisory position of any sort is usually in a With more than 30 years of experience in the gear industry, Terry McDonald is a manager better position to see the “whole picture” and with Repair Parts, Inc., a partner with Re-New Machine & Maintenance, Inc., and a current act on potential hazards, so their input should member and past-chairman of the American National Standards Institute B11.11 be larger but not treated any differently. Subcommittee on Safety Requirements for Construction, Care, and Use of Gear Cutting What should you do when a potential haz- Equipment. McDonald writes this monthly column specifically for Gear Solutions magazine. ard is presented to you? Do you thank the He can be contacted through the magazine at [email protected]. Responses and reactions to his column are also welcome. person for bringing it to your attention? Do

10 GEAR SOLUTIONS • OCTOBER 2004 • gearsolutionsonline.com andyMILBURNandyMILBURN PP.E..E. President of Milburn Engineering, Inc.

4. During and after disassembly, visually examine all of the components using a TOOTH TIPS bright light and a 10X magnifying glass. Think like a detective when it comes to determining the cause of equipment Inspect and document the condition of failure... keep an open mind, and be sure to preserve all of the evidence. the parts prior to any cleaning and then, It’ll pay off in the long run. if necessary, clean the parts for further inspection. hen failures occur, especially on a lubrication equipment. • Record identifying numbers on all piece of critical equipment, the first • If the gearbox has already been disassem- components. W priority is usually to get the equipment bled, collect all of the failed components • Thoroughly examine all of the gearbox operating again. Unfortunately this can result in the loss of valuable information as and the breather, oil filter, and as much of components for areas of pitting, fracture, to the cause of the failure and lead to more the debris as possible. Don’t clean any- polishing, fretting, and abrasive wear. failures down the road. thing or touch fractured surfaces. It is also • Determine the failure and wear modes. During the investigation, remember that pit- important to prevent the parts from being Several helpful references are: ting or bending failures occur because the mate- contaminated or corroded. A) “Failure Atlas for Contact Machine rial strength is too low or the applied local • Collect several oil samples in clean oil- Elements” by stress is too high. Wear failures are generally sample bottles. T. E. Tallian, 2nd Edition 1999 caused by lubrication problems. Take lots of B) ANSI/AGMA 1010-E95 “Appearance photos and notes regarding the condition of 2. Collect information regarding the of Gear Teeth-Terminology of Wear components and avoid jumping to conclusions operation of the gearbox prior to the failure. and Failure” 1995 too early. Sometimes what looks like an obvious • Determine the time of the failure and all C) Gear Failure Atlas by GEARTECH - reason for the failure is really secondary dam- operating parameters such as temperature, Townsend, MT c1999 age caused by the initial failure. If the situation vibration levels, speed, and applied load. warrants, make a cause-and-effect or “fishbone” • Interview operators and maintenance per- 5. Determine if the failed components diagram to guide you during the investigation. sonnel for their observations and com- were manufactured properly by sending Each situation is unique and will dictate the ments regarding unusual noises, vibration, them out for inspection. exact procedure, but some general guidelines or other conditions prior to the failure. • A metallurgical lab can examine the are as follows: • Collect all maintenance records that failed parts using high magnification to show previous repairs, alignments, determine the failure initiation points and 1. As soon as possible after a gearbox inspections, oil changes, and oil analysis. more detailed information on wear and failure, visit the site to start the inspection. failure modes. • If the gearbox is still installed, make sure 3. If possible, move the gearbox to a clean • Have them check the material composition, that it’s locked out and can’t rotate unex- and well-lighted facility for disassembly and hardness, microstructure, and cleanliness pectedly, and be sure to follow all factory a detailed inspection of the components. to determine if it met original specifications. safety procedures. • Prior to and during disassembly, mark all • Failed gears can be sent to a gear lab to • Record all of the information from the components with identifying information determine their dimensions and accuracy. nameplates of the prime mover, gearbox, such as the gearbox serial number using • Send oil samples out for analysis to and driven equipment. a vibrating pencil. Mark the position and determine the condition of the oil and lev- • Examine the outside of the gearbox for orientation of all components in relation els of wear metals and oil additives. evidence of loose bolts, oil leaks, over- to one another prior to disassembly, heating, or a broken housing. including the orientation of bearing inner After test results and observations are • Check the alignment of the high-speed and and outer races with their mating parts. completed, select the most probable cause low-speed shafts with the mating equip- • Measure and record the torque required of the failure and take steps to prevent ment and the condition of shaft couplings. to loosen all fasteners. future occurrences. • Check for the proper installation and condition of all monitoring equipment, such as temperature and vibration. ABOUT THE AUTHOR: • Check the oil level and for the proper Andy Milburn P.E. is president of Milburn Engineering, Inc. and has over 29 years of experience installation and operation of any external in the gear industry. He can be contacted at (206) 365 2818 or [email protected].

gearsolutionsonline.com • OCTOBBER 2004 • GEAR SOLUTIONS 11 company Profile

PPPAYINGAYINGAYING ATTENTION ATTENTION ATTENTION TO TO TO DETAILSDETAILSDETAILS AND AND AND GROWING GROWING GROWING INININ A A A METHODICAL METHODICAL METHODICAL MANNERMANNERMANNER HAS HAS HAS ALLOWED ALLOWED ALLOWED DDDANANAN SSSCHWARTZCHWARTZCHWARTZTO TO TO BREAKBREAKBREAK FROM FROM FROM THE THE THE PACK PACK PACK ANDANDAND EMERGE EMERGE EMERGE AS AS AS AN AN AN AAAMERICANMERICANMERICAN SUCCESS SUCCESS SUCCESS STORY STORY STORY... By Russ Willcutt RAYCARRAYCARRAYCARGEARGEARGEAR &&& MACHINEMACHINEMACHINE CO.CO.CO.

12 GEAR SOLUTIONS • OCTOBER 2004 • gearsolutionsonline.com ifteen years ago Dan Schwartz found himself in a bit “Besides, that’s the only way I know how to go about of a professional quandary, caught somewhere doing things,” Schwartz says. “I’ve always believed that if I between the shop floor and a glass ceiling. “I’d did a good job and satisfied my customers, then the work spent about eight years working my way up from run- would come to us and we would grow. And that’s exactly ning machines to middle management at a company what’s happened.” F called Patterson Gear,” he says. “That’s when I real- Growth came quickly in the early years, in fact. In order to izedFF I wasn’t satisfied with either position and there was attract new business, the partners needed more equipment, nowhere left for me to go.” and it wasn’t long before they’d completely run out of Nowhere within that company, at least. The solution? “I space. “I was out driving around one Saturday, and I saw started looking around, and I found this little business what looked like the perfect building,” Schwartz recalls. “So called Raycar Tool & Machine,” he says. “I met with the guy I contacted the owner, and by Monday morning we had the who owned it, and he was interested in selling, so I talked banker and a lawyer out there and we bought the building. It with a buddy of mine at Patterson who agreed to come on doubled our space to 5,000 square feet, and it just seemed as a silent partner, and we ended up buying the company endless when we moved in. We didn’t think we would ever for $50,000.” run out of space again.” What that bought them was a machine shop that had once As it turned out, by the end of that year it was time to been owned by two brothers—Ray and Oscar, thus the name double the company’s size once again by purchasing the “Raycar”—and was in a fairly advanced state of decline. building next door for a total of 10,000 square feet of man- “The building was just 2,500 square feet with a couple of ufacturing space. But a lot had happened during that time. antiquated machines sitting around, and the company didn’t The first involved renaming the company as Raycar Gear & have any customers to speak of,” says Schwartz, “so we Machine in order to reflect its new direction, and the second really started at ground zero.” It wasn’t long before he realized that a change needed to be made in order for the business to have a chance of succeeding. Located near Chicago, in Rockford, Illinois, there were hundreds of machine shops vying for every scrap of business. “With all these guys low- balling each other on every job, there just wasn’t any money to be made, and going broke really wasn’t what I’d had in mind when I got into this whole thing,” Schwartz says with a laugh. He soon came up with a plan: He would present his partner with a choice, asking him to decide between throwing in the towel and liquidating the company’s assets, or coming onboard full time and getting into the gear manufacturing business. “We had both worked our way up at Patterson, and we both knew a lot about gears,” says Schwartz. “So he quit his job, joined the company as a full partner, and we started buying Raycar’s Hofler Helix Gear Grinder gear equipment.” Inside view of the Hofler Helix Gear Grinder Curiously enough, one of their first customers was their former employer, who sent some business their way since both men saw Schwartz buying out his partner to become had left the company on good sole owner of the business. “It wasn’t a falling terms. Also, Schwartz’s sister met a man who was looking for out or anything, we were just headed in different direc- someone to do some machining for him. “She got his card, tions,” he says. “We’re still friends and have tremendous and I was on the phone with him the next day,” he says. “So respect for each other to this day.” that’s how we got through those first few months, with orders Since then Raycar has continued its trend of careful, qual- we’d pick up here and there, and we just sort of slowly start- ified growth, making sure that its current customers’ needs ed building up a name and a reputation for doing good work. have been met before taking on new work. This approach

gearsolutionsonline.com • OCTOBER 2004 • GEAR SOLUTIONS 13 has proven successful, “I’VE ALWAYS BELIEVED THAT Schwartz says, “I’“I’VEVE ALWAYS ALWAYS BELIEVED BELIEVED THAT THAT with little need IF DID A GOOD JOB AND for outside rep- IFIFIII DIDDID A A GOOD GOOD JOB JOB AND AND resentation. “My wife, Joy, SATISFIEDSATISFIEDSATISFIED MY MY MY CUSTOMERS CUSTOMERS CUSTOMERS,,, has taken on responsibility THENTHENTHEN THE THE THE WORK WORK WORK WOULD WOULD WOULD for sales in the past few COMECOMECOME TO TO TO US US US AND AND AND WE WE WE WOULD WOULD WOULD months, and we now make sales GROWGROW.. AANDND THAT THAT’’SS EXACTLYEXACTLY calls together, GROW. AND THAT’S EXACTLY which is working WHAT’S HAPPENED.” out very well,” WHATWHAT’’SS HAPPENEDHAPPENED.”.” he says. So much so that the company is doing business with industry giants such as Hamilton Sundstrand, which has a manufacturing facility nearby. “It was the same situation as always,” he says. “A guy who was pleased with our work said to one of their engineers ‘If you need something done right, give Raycar a call,’ and before we knew it we had 10 or 15 people from Hamilton Sundstrand calling us to manufacture their parts.” Schwartz says that the company has gradually developed into a supplier of OEM replacement parts for industries including printing, agriculture, and mining. Most gears are made complete from bar stock, with all operations performed in- house, and with an emphasis on low-volume, high-quality parts. This has been central to Raycar’s success, he adds. Still, between the outsourcing of jobs and a stalled economy, recent years have been hard on American manufacturing, and Raycar has taken its lumps along with everyone else. Convinced there would be brighter days ahead, however, Schwartz decided to take advantage of the downtime to mount an investment initiative. “Three years ago I started a program of purchasing new equipment for the company,” he says. “I traded in two old CNC lathes for two new ones, and I bought a new gear grinder and a CNC OD grinder, along with some other pieces of equipment. So I’ve ended up rein- vesting about a million dollars back into the company.” That investment is now showing a return. Since the first of the year, Schwartz says that business has taken off, to the extent that he is operating at full capacity and already in need of new equipment and more space—both of which are

14 GEAR SOLUTIONS • OCTOBER 2004 • gearsolutionsonline.com on the drawing board. “I wanted to be ready when business picked up, so I’m glad I made that decision,” he says. “Our sales have increased tremendously in recent months, and all indications are that we’ve finally turned the corner.” With 18 employees currently on the payroll, more will soon be needed, but they will be chosen carefully—in the same way that everything is done at Raycar. “It’s important that we choose the right people because we retain who we hire. We cross-train everybody so that they will be more valuable to the company, and we assign new hires to an employee mentor who can help them and answer their questions immediately,” Schwartz says. “We have no middle management here. We have Joy handling sales and Carl Wedig, who is my right-hand man and oversees operations, and me. Employees either work problems out on their own, or they come straight to us.” Schwartz says he has spent time in middle management, after all, “and I know how ineffective that can be.”

FOR MORE INFORMATION Call Joy or Dan Schwartz at (815) 874-3948 or send e-mail to [email protected]. Visit the company’s Web site at [www.raycargear.com].

gearsolutionsonline.com • OCTOBER 2004 • GEAR SOLUTIONS 15 << Drive Gear Gating through the center bore of this drive gear ensures uniform alloy distribution for consistent fill of the thread and gear tooth forms. The drive gear is cast ready to use with no finishing or deburring operations required.

16 GEAR SOLUTIONS • OCTOBER 2004 • gearsolutionsonline.com Cost savings, or many applications, zinc alloy die cast gears provide suming process, and the a streamlined an opportunity to dramatically cut manufacturing costs project management and improve part-to-part consistency. The cost of simple team was concerned production spur gears, as well as complex helical and worm gears, about inconsistent can be cut by up to 80 percent. Die casting can enhance runout and the accurate process, Frack gear performance by incorporating features unattainable positioning of the gear by other manufacturing methods. teeth relative to each and increased Bold statements? Not really. High pressure, hot chamber die other. Tooling con- quality are casting machines and high precision tooling debunk the myths straints and tolerance that many have considered to be the limitations of the die control issues precluded only a few of casting process. Extremely tight tolerances can be held over the use of powdered long production runs, and gears are cast net-shape and flash metal. Tolerance and the reasons free, ready for use with no secondary finishing operations strength concerns ruled required. And precision die casting leaves no room for varia- out the use of plastics. why die casting tions. Part to part consistency is inherent in the tooling. Die casting tool tech- The complex geometry of a newly designed horizontal gear nology presented an is an excellent drive used in an automotive seat adjustment mechanism opportunity to combine challenged design engineers in finding a cost-effective manu- the individual compo- alternative for facturing solution. With a worm gear at one end of a bearing nents—the worm gear, manufacturing journal and a helical gear at the other, the gear drive required helical gear, internal bear- precise tolerancing. ing journal, and two small gears. Production options included machining, but this required thrust faces—into a sin- production of two separate components in two separate gle zinc alloy die casting. By Stuart Burke operations, plus press fitting with a spline engagement to The material provided complete the assembly. This would be a costly and time con- the strength and dimensional stability required, and the process cut production costs by 40 percent compared Gear Group >> to machined steel. Tooling design incorporates four side cores A wide range of small which come together to form the worm gear cavity, while gating gear forms can be die through the center bore ensures uniform alloy distribution for cast in a choice of zinc consistent fill in the tooth forms. The gear drive is cast ready to alloys. The double gear is use, with no finishing or deburring operations required. formed in a single die The ability to convert multiple components and operations cast operation. A spur into a single operation is one of the major reasons for consid- gear can be cast for as ering the die casting process. However, die casting offers many little as 20 cents, and other opportunities to cut costs and increase quality. the helical gear is cast net shape for a fraction of the cost of milling. Why Die Casting? The potential for piece price reduction usually drives the move to high volume die casting production. Economics start at 50,000 pieces per annum and relate to a number of factors

gearsolutionsonline.com • OCTOBER 2004 • GEAR SOLUTIONS 17 << Rack and Pinion To provide superior strength, hardness, and creep resistance to a gear rack for a window security system, ACuZinc® zinc alloy was selected, but ribs were added on either side of the rack to increase strength and performance.

such as component complexity, alloy properties, die casting part name/number; and manufacture date or other identify- technology used, precision of the die cast tool, and cycle rate. ing information are included in the casting cavity. In addition to being able to replace multiple components, The ability of die cast tooling technology to produce very secondary milling, boring, reaming, and grinding can be complex gear shapes at a high production rate provides oppor- eliminated by incorporating features as part of the casting. tunities to increase functionality at reduced manufacturing Flash-free die cast tooling means no finishing. Additional costs. High tolerance helical gears, up to a 28 degree angle, can savings come from material reduction, use of less expensive be cast in a single tool at a slight premium to simple spur metal, improved tolerances, and part to part consistency. gears. For many applications, this provides the opportunity for better transmission performance and reduced noise. The die casting tool for a helical gear is designed to rotate as the cast What Can Be Die Cast? part is ejected, in much the same way as a screw is backed off. The greatest process benefits are realized when requirements A punch-out center gating technique ensures uniform distribu- call for complex configurations, close tolerances, and part to tion of the zinc alloy to provide good detail and consistency in part consistency. Die casting reduces manufacturing costs for tooth forms on the outside circumference, and forms a semi- external, internal, face, helical, spur, and worm gears, casting burnished through hole to tight tolerances. them to AGMA 6 to 8 specification. Most tooth forms can be When the moveable and fixed halves of the tool close, molten cast, including teeth with helix angles as great as 20 degrees. zinc alloy is injected into the cavity around the center hole cir- Up to 50 external threads/in. are cast flash-free to Class 2A cumference, which can measure from .060” to .320”. After the tolerance without cleaning or chasing, as are multi-start molten alloy solidifies, a highly polished core rod, which forms threads. Internal threads can be cast to .001”. the center hole, advances from the moveable side of the tool. As it Even a simple spur gear can be die cast at a fraction of the advances, it punches out the sprue, or gate. The core rod then cost of machined gears: approximately 80 percent less. While retracts, leaving a semi-burnished hole that is cast to a dimension- the savings are not as substantial in comparison to powdered al tolerance of ± .0005”, with walls parallel within ± .0005” and a metal, aluminum cast, and stamped gears, much finer tooth mirror-like surface finish of between 0.1 and 0.2 microns. forms can be die cast net shape. But die cast zinc alloys in Depending on application requirements, a worm gear as this simple spur gear configuration cannot compete with described above is also an excellent candidate for zinc alloy plastic gears from a cost standpoint. die casting. The parting lines (where the side cores of the tool Double spur gears can be easily cast net shape, eliminating meet to form the gear shape) are precisely placed and con- multiple milling and hobbing processes, as well as the under- trolled to a mismatch of less than .002”, but limit tolerance cut required. A gear can also be cast directly onto any vertical capabilities to AGMA 5. face. During the casting process, other features can be incor- Die casting of rack gears allows features such as side ribs to porated which replace the need for additional operations. be incorporated into the die cast design. To provide superior Indicator and timing marks, either embossed or recessed; strength, hardness, and creep resistance to a gear rack for a window security system, ACuZinc® zinc alloy was selected, but ribs were added on << Worm and Helical Gear either side of the rack—not only to increase Die casting tool technology strength, but also to provide a guide to the presented an opportunity pinion gear to improve performance. A flat- to combine the individual ness tolerance of .006" and a gear pitch tol- components—a worm erances of ± .002" are held consistently gear, helical gear, internal through long production runs. bearing journal, and two thrust faces—into a single zinc alloy die casting. Zinc Alloy Choices Strength and wear properties of the die casting alloy required for the application’s function, plus the mating surface, are determining factors in selecting zinc alloy as the

18 GEAR SOLUTIONS • OCTOBER 2004 • gearsolutionsonline.com material of choice for die cast gears. part-to-part consistency over long pro- As mentioned previously, the mating Zinc alloys, such as those in the duction runs. Net shape manufacturing surface may exclude use of zinc alloy. A ZAMAK, ZA and ACuZinc families, offer is one of the main advantages of hot glass-filled nylon or plastic mating a wide range of good casting character- chamber die cast zinc alloys. part, or one with an abrasive surface, istics*. Zinc is the strongest die cast Zinc alloys do have limitations for will quickly wear the zinc alloy gear. alloy at room temperature. Hot cham- certain operating environments. They The most commonly used zinc alloys in ber die cast zinc alloys can be cast flash- are not suitable for high loads and the hot chamber die casting process are free to tight tolerances with complex high temperatures. With sustained ZAMAK 2, ZAMAK 3, ZAMAK 5, ZA-8, and detail. Dimensional stability ensures loads, alloy creep can become an issue. ACuZinc. Overall, their mechanical properties compare favorably with powdered iron, brass, and screw-machined steel. ZAMAK 3 is the most widely used zinc alloy as it offers the best combina- tion of mechanical properties and economics. ZAMAK 2 and 5, with higher copper content, exhibit better wear resistance, although some dimensional stability is lost. ZAMAK 5 offers a higher creep resistance, but ZAMAK 2 has the highest shear strength. The newer high aluminum and copper content ZA alloys have greater strength, superior wear and creep resistance, and lower densities. ZA-8 is the only member of this group that can be cast in the high speed, hot chamber die casting process. ACuZinc, with a copper content of 5 to 6 percent, has the highest structural strength, greater hardness, creep resistance, improved wear and corrosion properties, and lubricity. ZAMAK 2, with its high tensile strength and lubricity, comes a close second to some of ACuZinc’s properties and may be a suitable alternative in particular applications. Consistently close tolerances are char- acteristic of the hot chamber die casting process. For a typical 1” component with Cpk = 1.33, linear die cast tolerances, flatness and roundness are as close as .001”, and concentricity to .002”. ACuZinc has extended zinc alloy’s use to structural applications because of its creep resistance, with a yield strength of 338 MPa. However, ZAMAK alloys can also be suitable for some load applications, as additional creep resistant properties can be designed into the component. Zinc alloys, in particular ZA-8 and ACuZinc, have significantly greater hardness than other die casting materials, with a Brinell hardness of up to 103 and 118 respectively. ACuZinc’s low coefficient of friction makes it usable for bearing applications, but ZAMAK 2, with a Brinell hardness of 100 and high lubricity, can also be considered for bearing conditions.

20 GEAR SOLUTIONS • OCTOBER 2004 • gearsolutionsonline.com The properties of zinc alloy give The OEM reduced production costs by mixers are reduced to one die casting enormous flexibility in selecting a die replacing the pre-manufactured plastic cam operation. Rather than press fitting a 2 1 casting material. Each must be exam- and steel pinion with inexpensive zinc alloy, ⁄2” die cast gear and a 1 3/8’ sintered 1 ined on its own merit. While similar in reducing labor requirements. Product quali- iron bevel gear separately to a ⁄2” diam- many respects, they exhibit sufficient ty is also improved. Shaft to gear runout is eter and 4” long steel shaft, then pin- diversity to meet a wide range of appli- consistently held to .008”, and shaft to cast ning through and across them, the cation specifications for small compo- hub runout is .003” maximum. three components are assembled and nent manufacturing. In addition, their Multiple operations in the produc- locked into position with an injected castability opens opportunities for tion of motor drive assemblies for food zinc alloy joint in one operation. This component cost reduction.

Thinking Outside the Die Design engineers need to think beyond die casting as simply the forming of metal components. At its simplest, that is what it is. But its real benefits are realized when die casting is used as a manufacturing process to reduce production costs. Where an application consists of several parts, the die-cast caster will look for ways to combine them into a single component, consolidating gears with shafts, ratchets, and cams. Applications that require swaging, riveting, screw machining, stamping, press-fitting, welding, or assembly of one or more parts can be die cast in one operation. The original design of a gear and shaft assembly consisting of a plastic cam, steel pinion, steel shaft, and fine blanked steel gear required one staking and two press fitting operations. The assembly was expensive to produce, and there were con- tinuing problems with the shaft to gear and the shaft to cam runout. Combining die casting technology with assembly techniques, production becomes a single operation, and pre-manufactured components are eliminated. The gear and shaft are loaded into a specially designed assembly (fixturing) tool which positions the components in their correct relationship. Molten zinc alloy is injected under pressure into a cavity at the intersection which is in the shape of the cam and pinion. The molten metal solidifies in milliseconds, shrinking toward its theoretical center and mechani- cally locking the gear and shaft together with the zinc alloy cast cam and pinion. The precision of the tooling casts the configuration net shape and flash-free, so secondary finishing operations are not needed. For this application, a diamond knurl on the shaft provides additional strength to the assembly. In strength tests, the gear and shaft components fail before the zinc alloy hub.

gearsolutionsonline.com • OCTOBER 2004 • GEAR SOLUTIONS 21 eliminated costs and quality problems associated with drilling scrap is common to pressure die casting. Tooling techniques and pinning, as well as cleaning. The die casting process allow production of intricate and complex external and inter- ensures part to part consistency over long runs, maintaining a nal shapes to very close tolerances (.001”.) and net shape. tolerance on the shaft position to within .004” T.I.R., and con- The flash-free capability alone can offset tool costs because centricity of the gear OD and the shaft OD to .002” T.I.R. secondary finishing or machining are not required.

Choosing a Process Getting Started The choice of alloy dictates the die casting process, as does It’s a smart idea to have a die casting supplier on board as the size of the component. Pressure die casting is the most part of your initial project planning team to ensure the common method of producing small zinc alloy components, design incorporates the necessary die casting requirements using either the hot chamber or cold chamber process. Small and specifications. Most suppliers have technical specialists zinc alloy die cast gears are produced in the hot chamber whose sole job is to review component designs for die cast- process, which allows the very precise tolerancing and flashing. Value engineering can translate into major cost savings free, net shape required for high performance, intricate in both design and production by maximizing tooling and shapes. Zinc alloys with a high aluminum content (ZA-12, die casting techniques. ZA-27 and ACuZinc-10) are not suitable for hot chamber die Before the design can be finalized, the die casting supplier casting and must be cast using the cold chamber process. must calculate process factors such as flow vectors, gate and The die cast methods for each metal have merits and limi- runner design, fillets, radii, draft, metal velocity, and fill time. tations, depending on component size and complexity, toler- Die casters can employ a number of techniques to maximize ance specifications, production volume, and tooling cost. tool and component design. Even minor changes can Overall, hot chamber pressure die casting is the process of improve performance and reduce costs. Elements such as ribs choice for production of small zinc alloy components (up to may be suggested to give the component increased strength, 6 cubic inches). For larger components, other casting process- stability, and density, while at the same time wall thickness es need to be evaluated. While initial tool costs are high for can be cut to as little as .020”. Where weight is a concern in the hot chamber process, large volume production and part gears used in precision measuring instruments or gauges, a to part consistency reduce piece price. Zero parts per million cross-section can be reduced and/or recesses designed into

22 GEAR SOLUTIONS • OCTOBER 2004 • gearsolutionsonline.com the component to remove material. The addition of extra A die casting tool is basically a six- ABOUT THE AUTHOR: threads in a bolt connection will reduce creep and ensure sided cube that opens and closes like Stuart Burke is an that the load is retained over a long period of time. a clam shell, with a parting line application engineer for Gating is a critical issue, particularly with die cast gears. With where the two halves meet. Within FisherCast Global most component configurations the molten alloy is injected that cube is the cavity in the shape of Corporation, which is into the cavity along a parting line on a non-critical feature. the component to be formed. Any located in Peterborough, With spur, helical, bevel, and worm gears, the alloy flow to fill component feature parallel to that Ontario, Canada. He can the teeth forms is augmented by a center gating technique which open/close motion is easily incorpo- be reached at (800) introduces the alloy into the cavity around the circumference of rated into the two halves with the 547-6905. The company’s a through-hole which can be .400” or less in diameter. use of cores. For example, a fixed Web site is core pin in the moveable half of the [www.fishercast.com]. tool forms a center hole. For features Tooling Techniques offset from the parting line, move- Very complex component configurations with intricate fea- able side cores are driven in a sideways motion to be retracted tures are common to pressure die casting through sophisti- before the die cast component is ejected from the tool. These cated tool building. The tolerance of the tool itself is critical, cores can be at any angle. For a wheel that requires features on as flashing at the tool faces can defeat the economics of die the outside diameter corresponding to each month of the year, casting when deburring or secondary finishing has to be per- 12 cores are used, one every 30 degrees. formed. In conventional die casting tools, molten alloy is Cylindrical cores form holes with a .001” tolerance, which forced into the cavity until it flashes out between adjoining can be tapped to 60 - 75 percent full thread without drilling. surfaces. In the small component zinc alloy die casting Side cores enable the production of holes and undercut fea- process, tools are assembled to tolerances of ± .0001”, clos- tures that are parallel to the major parting line of the tool. A ing to form a very tight seal around the cavity that eliminates movable core can form a hole or slot of virtually any shape flash. This precision accounts for the ability to hold part to to tolerances of .002”. Center bores can be cast to a dimen- part consistency over large production runs. sional tolerance of ± .0005”.

* ACuZinc is a registered trademark of General Motors Corporation. ZAMAK and ZA are trademarks of Eastern Alloys, Inc.

LARGE 75,000 SQUARE FOOT FACILITY AND GROWING

C-B GEAR & MACHINE, INC. is committed to providing products and services that meet or exceed customer’s needs. On-going training and utilizing the latest innovations enables us to continuously improve our quality and reliability at competitive prices. Our complete machining and gear cutting capabilities provide for effective processing and quality control, as well as reduced lead times. And with our new climate-controlled gear grinding room, we are able to validate the quality and precision of the gears we produce. C-B Gear & Machine, Inc. 4232 MOONEY ROAD • HOUSTON, TX 77093 1-800-428-6028 281-449-0777 FAX 281-590-9127 EMAIL US AT [email protected] OR VISIT OUR WEBSITE AT WWW.CBGEAR.COM

gearsolutionsonline.com • OCTOBER 2004 • GEAR SOLUTIONS 23 24 GEAR SOLUTIONS • OCTOBER 2004 • gearsolutionsonline.com engineering principles for PLASTIC GEARS By Rudy Walter

In many instances, plastic materials perform markedly better than do metals—especially in gears. Read on to learn the details that will allow you to make the best choice for your operation.

ince founding Timco in 1967, I’ve been riding a mating surfaces of high quality), absorbs less moisture steep learning curve regarding plastic materials and and is dimensionally more stable, but it is also less suit- the machine parts that we make from engineered able for small precision gears. plastics. Just when I thought that this strenuous 3) PA 6 G (Cast Polyamide 6): the high degree of crystal- curve was about to level off due to my retirement, lization makes PA 6 G especially wear resistant. Smy colleagues asked me to write about machined plastic 4) Calaumid 612/612-Fe® (cast PA 6/12): this polyamide gears. I hope this information will be useful to you. is engineered toward toughness against shock loads, The following is written for metric gear calculations, and some with wear resistance similar to PA 6 G. (Calaumid is a of the metric terminology has been retained. As an example, the Timco exclusive) term “modul” can be equated with “diametrical pitch.” 5) Calaumid 1200/1200-Fe® (cast PA 12): a lower degree of moisture absorption gives better dimensional stability. It has excellent wear resistance and withstands high shock loads. Plastic Materials 6) PA 6 G + Oil (Cast Polyamide 6 + Oil): the addition of Properly selected plastic materials offer better performance lubricating oil into the PA 6 G provides very good dry than metals when all or some of the following requirements running and wear resistant properties. must be satisfied: 7) POM-C (Polyacetal-C): this Acetal absorbs very little moisture, which makes it suitable for precision gears, • Low maintenance but it needs continuous lubrication under high loads. • Wear resistance when running dry 8) UHMW-PE (ultra-high molecular weight polyethylene): • Low noise PE absorbs no moisture, is dimensionally stable, resist- • Vibration dampening ant against chemicals, and dampens vibrations, but it is • Corrosion-proof suitable only for low loads. • Low inertia due to low rotating mass, light weight • Low manufacturing cost There are limitations of speed and load for plastic gears, of course. Metal gears usually operate well within the tempera- Polyamides can be engineered toward one or more require- ture limits of the material. The design of plastic gears, howev- ments, as is shown by the following listing of the plastic er, must always take into consideration the increase in tem- materials most commonly used for manufacturing gears: perature which is caused by friction, pressure, and speed. The following paragraphs will show how one’s design can safely 1) PA 6 (Polyamide 6): this material is wear resistant and stay within these limits. absorbs impact even under rough conditions, but it is less suitable for small precision gears. Quality of Mating Gear: 2) PA 66 (Polyamide 66): compared to PA 6, this extruded The gear which mates with a plastic gear can also be of plastic, polyamide offers better wear resistance (except against but only in slow and lightly loaded applications. Otherwise,

gearsolutionsonline.com • OCTOBER 2004 • GEAR SOLUTIONS 25 case-hardened steel is the best mating material because it dissipates run-in period. The waviness may even offer lubricant pockets, friction heat quickly. The harder the steel, the slower the wear on but it does not lower the quality of the gear. the gear wheel and pinion. We recommend a surface quality of Depending on the modul, gears of AGMA 9-10 qualities can Rt = 8 to 10 µm, both for dry and lubricated applications. be achieved with the milling of plastic gears. Timco manufac- The driving pinion is always subject to greater wear, there- tures plastic gears both according to metric standards and fore the pinion should always be of the more wear resistant according to ANSI. The load bearing surfaces of plastic gears are material (e.g., steel pinion/plastic gear wheel; PA pinion/ somewhat pliable, and wider tolerances can be allowed due to POM gear wheel). the elasticity of the plastic. Therefore, compared to steel gears, the quality of plastic gears can be reduced by up to two AGMA Lubrication: grades. The backlash may be increased—compared to steel Automatic lubrication will improve the break-in performance gears—by one to two quality grades in order to allow for the and the overall lifetime considerably. Plastics which are engi- effect of temperature and moisture upon the plastic. neered with oil additives—such as PA 6 G + Oil—provide much longer lifetimes than all other plastics. Continuous oil lubrication results in better friction heat dissipation and Design Details longer useful lifetime, or higher load bearing capacity. With This article concerns itself mainly with spur gear design. grease lubrication, the circumferential speed should not be However, plastic can also be used for bevel gears, step gears, higher than 5 m/sec so that the gear does not sling off the herring bone gears, worm gears, and others. grease. We do not recommend that you lubricate polyamides with water because the material tends to absorb water. Face Width: The face width of a plastic gear tooth may be as wide as the Noise Generation: gear diameter. The minimum width is limited by the axial The excellent noise dampening properties of plastics result in a stability of the gear wheels. We have no test results for the quieter-running gear. The graph below shows noise generation connection between face width and lifetime, or about the in dB of steel against steel “a” and of steel against plastic “b” at most-efficient face width. However, our experience in many increasing speeds. The difference is as much as 9 dB. Steel applications indicates that face width should be at least six to against steel generates up to three times as much noise than eight times the modul of the gear. does steel against plastic. Noise equals wear: When we replaced When mating steel and plastic, the plastic gear face should the noisy steel pinion gears in the drying section of a paper mill be slightly narrower than the face of the steel gear. The plastic with PA6G gears, the noise disappeared, and one could stand a gear is then contacted under load over its entire width, and nickel upright on the housing of the running gear. no groove can be worn into the plastic face.

Module, Pressure Angle, and Number of Teeth: The load bearing capacity of plastic gears is directly affected by the choice of modul and pressure angle. The root strength of the teeth increases if the modul or pressure angle is increased while the transmitted force stays the same. This increase is smaller with plastic gears because the contact ratio decreases and it is no longer possible to engage several teeth simultaneously. A higher contact ratio, however, can be better for increasing the load bearing capacity, rather than increasing the root strength of the individual tooth: For tough elastic thermo- plastics, a small modul is preferred (contact ratio increased, several teeth engage simultaneously). For hard thermoplas- tics, a large modul is preferred (root strength of the teeth is increased because a higher contact ratio is not possible with the hard material). The pressure angle for involute plastic teeth is defined at 20°. Pressure angles <20° result in thinner teeth of less load capacity, with steep tooth profiles but low running noise. Pressure angles >20° produce more-pointed, thicker teeth with greater root Manufacture of Plastic Gears: strength. The ratio of the number of teeth in high speed gears Plastic gears are manufactured with the same machining should not be an integer multiple. The same teeth should not process as are metal gears, usually milling or hobbing. The always engage, because this would promote accelerated wear. very low cutting forces permit high infeed rates. This reduces manufacturing cost. Milling with high rates of infeed may Helical Gearing: produce a wavy, rough surface which may seem detrimental Helical plastic gears run quieter with a small helix angle than to long-term performance. However, the load bearing sur- do spur gears. The increase in load capacity, however, is faces of the plastic teeth will become smooth during a dry smaller than would be expected with steel gears. The face

26 GEAR SOLUTIONS • OCTOBER 2004 • gearsolutionsonline.com contact line may be longer and several teeth engage simultaneously, but the load is distributed unevenly and the teeth get deformed. Helical plastic gears are calculated like metal gears, using a spur gear of similar size. β = 10° - 20° is the preferred helix angle.

Backlash and Clearance: The material-specific designing of backlash and clearance is important due to the high thermal expansion rates of plastic materials. A minimum backlash must be guaranteed. We recommend a minimum face clearance of about 0.04 x modul. Thus, the backlash at start-up is:

Se = Seo + 2 l sin α (kα · kF) [mm] Seo = minimum face clearance in mm l= total distance in the plastic material between the rotating axes in mm α = pressure angle kα = factor of elongation kF = factor for moisture absorption

We recommend an initial clearance of 0.3 x modul. This allows for temperature variations of ± 20°.C as well as for tolerance variations.

Power Transmission: Key and keyway connections are used for plastic gears, too. The load bearing side of the keyway must be dimensioned so that the permissible contact pressure of the plastic is not exceed- ed. This maximum contact pressure is:

3 Md • 10 PF = [MPa] i • rm • h • b

Ma = torque in Nm i= number of keys rm = radius from the shaft center to the center of the key way in the plastic, in mm h= height of the key in the plastic gear which engages the plastic in mm b= length of key in the plastic gear which engages the plastic in mm

The resulting value must be compared with Diagram 1. It may not exceed the values which are permissible for the specific plastic material. However, this value does not include a safety factor for shock loads or other reserves. We recommend a safety factor of between 1.5 and 4. Keyways in plastic should be machined with a radius in the corners, if at Diagram 1 all possible,

28 GEAR SOLUTIONS • OCTOBER 2004 • gearsolutionsonline.com because of the notch sensitivity of the i+1 k2 • 17100 k3 ϑ = ϑ + P • µ • 136 •• + 7.33 • [°C] plastic material. 1,2 U 3/4 z + 5i () b • z • (v•m) A There are several other designs for 1,2 1,2 connecting a steel hub to the plastic Where: gear. A press-fitted steel hub secured with bolts allows for keyways and keys Index 1 for the pinion designed according to traditional guide- Index 2 for the wheel lines for metals. Another very good alternative design is the material Calaumid 612 Fe® or Calaumid 1200 Fe®. The metallic core is securely connected with the plastic gear. Keyways and keys can again be designed according to traditional guidelines for metal.

Calculating Thermoplastic Gears Thermoplastic gears fail prematurely for mostly the same reasons, and with the same symptoms, as do gears made of steel. Therefore, the calculation of plastic gears does not use different methods. The only difference is the inclusion of material-specific properties in the form of correction factors. The calculations for torque, circumferential force, and circumferential speed use the formulas which apply to steel gears.

Estimated Tooth Temperature in Continuous Operation: Temperature plays a major role in estab- lishing the load capacity of plastic gears. The tooth body temperature sets the permissible loading and deformation of the tooth base. The tooth face temperature allows an approximation of the rate of wear. An accurate determination of both temperatures is difficult. The heat transmission coefficient on a rotating gear wheel can only be estimated approximately. Thus, the calculation of the tooth face temperature may sometimes result in a very high number; higher even than the melting temperature of the plastic. However, we have not yet observed a melting of plastic gear tooth faces. The following formula presents an estimate of the temperature of the gear. Because it is an estimate, the calculated temperature may sometimes result in a higher value than the actual temperature. This is used as an extra safety factor. The calculations below take into account the friction heat, the rate of heat dissipation from the gear, and from the gear housing to the outside. We arrived at the following formula:

gearsolutionsonline.com • OCTOBER 2004 • GEAR SOLUTIONS 29 Diagram 2

ϑU = ambient temperatures in °C P= power in kW µ= coefficient of friction z= teeth i= transmission ratio z1/z2 with z1 = number of teeth in pinion b= width of the tooth face in mm v= circumferential speed in m/sec m= module in mm Diagram 3 A= surface of the gear box in mm2 k2 = material-related factor 2 k3 = gear-related factor in m K/W

For factor k2 the following must be included depending on the temperature to be calculated:

Factor k2 :

k2 = 7 for mating components steel/plastic k2 = 10 for mating components plastic/plastic k2 = 0 in the case of oil lubrication k2 = 0 at v ≤ 1 m/sec

Factor k3 and the coefficient of friction µ:

2 k3 = 0 for completely open gear m K/W k3 = 0.043 to 0.129 for partially open gear in m2K/W k = 0.172 for closed gear in m2K/W 3 Diagram 4 µ= 0.04 for gears with permanent lubrication µ= 0.07 for gears with oil mist lubrication µ= 0.09 for gears with automatic lubrication Tooth Temperature in Intermittent Operation: µ= 0.2 PA/steel The load capacity of plastic gears increases if they operate intermit- µ= 0.4 PA/PA tently because less friction heat is generated. The relative duty cycle µ= 0.25 PA/POM ED is considered in the following equation by a correction factor f . µ= 0.18 POM/Stahl This relative duty cycle is defined as a percentage of the load time t µ= 0.2 POM/POM and the overall cycle time T

30 GEAR SOLUTIONS • OCTOBER 2004 • gearsolutionsonline.com Please note that each operating time which exceeds 75 minutes, even if this hap- pens only once, must be considered as continuous operation. Considering the correction factor f, we can calculate the tooth face temperature and the tooth body temperature:

i+1 k2 • 17100 k3 ϑ = 9 + P • µ• f • 136 •• + 7.33 • [°C] 1,2 U 3/4 z1,2 + 5i () b • z1,2 • (v•m) A

The values for k2 and k3 and, σF and σ•zul and the coefficient of friction µ can be taken from the preceding paragraph (“Continuous Operation”).

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Diagram 5

t ED = •100[%] T

t= total operating time under load within the cycle time T in min T= cycle time in min

A total cycle time T = 75 min has Mohawk Machinery has been helping companies get been established for thermoplastic MAXIMUM RETURNS on equipment gears. The sum of all individual oper- for more than 50 years. ating times under load during these 75 minutes is the total operating WE HAVE A VARIETY OF FLEXIBLE SERVICES time t. Using the value which resulted TO FIT YOUR NEEDS from this calculation, the correction factor f can be determined from CONSULTING Diagram 2. Customized marketing plans designed to meet your company’s unique business needs. APPRAISALS 150,000 SQUARE FOOT Take it to the bank: Accurate, USED MACHINERY WAREHOUSE expert equipment appraisals from AMEA-certified appraisers. • AUCTIONS ALL AT ONE LOCATION Over $44 million gross sales in the 2,500 MACHINES IN STOCK last three years. • LIQUIDATIONS TWO 50 TON P&H CRANES The right buyers...the right prices. • BROKERAGE RAILROAD SIDING A sensible, commission-based sales option. CONSIGNMENT A full-service partner you can depend on. STORAGE Secure storage at a reasonable price.

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gearsolutionsonline.com • OCTOBER 2004 • GEAR SOLUTIONS 31 Calculation of the Root Strength of the Teeth:

If the tooth root stress σf under load exceeds the permissible stress σ•zul, breakage of teeth is likely. Therefore the tooth root stress σ must be calculated and compared with the permissible values. The calculation must be made separately for either part where both pinion and gear are made of plastic. The tooth root stress is:

FU σf = • KB • YF • Yβ • Yε [MPa] b • m

FU = circumferential force in N b= tooth width in mm (use smaller width + m for the wider gear when widths of pinion and gear are different.) m= modul in mm KB = operating factor for variations in drive operation YF = tooth shape factor from Diagram 3 Yβ = helix factor to allow for the increased load capacity of helical gears

For plastic gears, use Yβ = 1.0 Yβ = contact ratio factor from table 1; Yε = 1/εα and εα = εαζ1 + εαζ2

For profile-corrected gears, the factor Yε must be adjusted accordingly:

Z1 εα = • (tanαε1 - tanαA1) 2 • π Diagram 6

There are many things to consider when placing an order with a gear manufacturer, such as trust, confidence and level of integrity.Spending money correctly is also a primary concern, but so is getting a reliable product, on-time that fits YOUR particular gear needs.

Being late due to lost time on the production line or receiving a poor quality product will NEVER happen with Carnes-Miller Gear, guaranteed! For over 30 years, we have maintained a strict quality control process. We make it easy for our customers to buy from us.We want each of our new or existing customers to have a positive, risk and worry-free experience.

Give us the chance to earn your business by letting us quote on your next order. At Carnes-Miller Gear, we assure you that we will handle your account and your projects, with professionalism and accuracy.

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

Carnes-Miller Gear... The Gear People® www.cmgear.com 362 Browns Hill Road • P.O. Box 268 • Locust, NC 28097

32 GEAR SOLUTIONS • OCTOBER 2004 • gearsolutionsonline.com The value tanαE1 is dependent on correction value: The values of tanαE1 and tanαA2 can be taken from Diagram 5. The effective pressure angles αtw and tanαtw are dK1 D1 = calculated from the profile correction x1,2 and the number of d G2 teeth z1,2 where Index 1 stands for the pinion and Index 2 for the large gear. The effective pressure angles for spur gears are Where: shown in Diagram 4. dK1 = outside diameter of pinion d = base diameter of large wheel G2 Calculation of Gear Face Load Capacity: And: Excessive gear face loading may cause pitting or excessive wear. This wear is concentrated at the root and crest of the Z2 Z2 tooth. It leads to a change in the tooth profile and, conse- tanαA1 = tanαtw • [] 1+ - tanαA2 Z1 Z1 quently, to uneven motion transmission. The tooth face pressure σ must be checked to determine The value tanαA2 is dependent on the correction value whether it is still within the permissible face pressure σH. This will preclude premature failure due to pitting and/or wear. dK1 D2 = For plastic gears the material factor ZM is added to the stan- dG2 dard formula in order to consider the plastic material: Where: FU • z1 +z2 σH = • KB • Z • ZH • ZM [MPa] dK2 = outside diameter of pinion ε b• d0 • z1 dG1 = base diameter of pinion √

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gearsolutionsonline.com • OCTOBER 2004 • GEAR SOLUTIONS 33 E1 • E2 ZM = √0,38 • E’ and E’ = E1 • E

E1 = modulus of elasticity for the pinion material E2 = modulus of elasticity of gear wheel material

This takes into consideration the different moduli of different materials of pinion and gear. The factor ZM for mating of plastic with steel may be taken from diagram 6. The mating of two plastic gear wheels results in ZM(K/K) 1 ZM(K/K) = • ZM(K/St) √2 If the gear wheel and pinion are made of different plastics, the factor ZM(K/St) which is valid for the softer plastic should be used.

Safety Factors: We recommend the following minimum safety factors,

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34 GEAR SOLUTIONS • OCTOBER 2004 • gearsolutionsonline.com Please contact Timco concerning the 3) Calaumid 1200/1200-Fe®: a pure diagrams for permissible tooth root PA-12 tough-hard polyamide with stresses and tooth face pressures (con- less moisture absorption and good tact information at end of article). dimensional stability that is suitable for shock loads, with metal Plastic Materials Engineered core to permit use of standard for Gear Manufacturing: steel keyways and keys. The three grades of polyamide listed at the beginning of this article are particularly applicable for manufacturing gears:

1) PA 6 G + Oil: a polyamide with ABOUT THE AUTHOR: an additive of lubricating oil Rudy Walter is the founder and retired which makes it most suitable for president of Timco, Inc., a manufacturer dry-running applications. and distributor of engineered plastic depending on the type of operation: 2) Calaumid 612/612-Fe®: a tough parts that is based in Peekskill, New • Normal operation: 1.2 polyamide for shock-load applica- York. For more information call (914) • Frequent reversals: 1.4 tions. It has a metal core which 736-0206 or send e-mail to • Continuous operation with stress allows the use of standard steel [email protected]. The company’s reversal: > 2 keyways and keys. Web site is [www.timco-eng.com].

gearsolutionsonline.com • OCTOBER 2004 • GEAR SOLUTIONS 35 By Fritz F. Greulich

With benefits including no heat buildup or chip problems, ROTARY SAW CUTTING has emerged as the premier process for producing quality gear blanks.

36 GEAR SOLUTIONS • OCTOBER 2004 • gearsolutionsonline.com stays cool, it doesn’t produce problematic chips, it rower than single point tooling so the kerf is reduced, thus cuts with ease…it’s the Super Tool! Well, not really. there is less material waste with which to contend. Again, It’s simply a rotating circular saw blade. But the circu- cutting with a circular saw is also an interrupted cut. It is, lar saw blade is too often overlooked as a possible therefore, absolutely impossible for a circular saw to produce tool when making parts turned from bar stock, such a sharp, stringy, coiled chip. The chips formed by a circular Itas gear blanks. Screw machine operators have forever struggled saw are coarse granules of material—they are not sharp, and with fine-tuning their single point tooling and set-ups in an they are compact, so removal, transport, and storage are easy attempt to produce better quality parts, to increase tool life, and and safe. Chip problems are eliminated. to reduce cycle times. Now, let’s be radical for a moment. What Other than no heat buildup and no chip problem, one if we could use a rotating tool with multiple cutting edges? other factor largely impacts the success of rotary sawing: low Well, that’s not so radical, as it turns out. Rotary Saw chip load. The chip load is negligible when using a saw Cutting (RSC) has been around for a long time, but has been because the workpiece and the saw rotate simultaneously. slow to gain popularity. Of course, a circular saw needs a Because the workpiece also rotates, the saw is always cutting mechanism to drive it. Over the years the attachments driv- a convex shape, so only one tooth cuts at a time and each ing the saw have become more reliable, consistent, self-suffi- tooth removes only a small amount of material. The lower cient, and powerful, and attachments are available to fit a chip load also helps to accommodate the higher feed and wide range of turning machines, so RSC is now more viable. speed rates attainable while rotary sawing. These increased Also, the advent of live tooling capability on CNC machines rates are possible without taxing the saw, so saw life is longer makes RSC a possibility without an additional investment; than single point tooling life. More importantly, however, simply mount a circular saw and go. low chip load accounts for better finishes, better tolerance Not only is RSC a viable reality, it is also far superior to control, and increased capabilities. single point tooling in its capabilities. The multiple cutting Part finishes are so dramatically improved when rotary saw- edges of a circular saw eliminate the problems of high heat ing that secondary operations are often not needed. A saw cuts buildup, undesirable chip formation, and high chip load. completely through the piece for a clean, smooth surface. The The result is a myriad of technical advantages that increase cutoff nib is virtually eliminated, and burr is significantly production levels, improve quality, and lower production reduced. Low chip load also affects tolerances. Tool and work- costs: more parts per hour, more parts per bar, better finishes, piece deflection are negligible, so surface squareness and flat- increased tool life, easier and less costly scrap handling, and ness are typically within 0.002” and often within 0.001”. increased machining capabilities. Finally, low chip load greatly increases the host machine’s A rotating circular saw cutting through a rotating bar of stock capabilities, cutting irregular shapes, cutting exotic materials, builds up very little heat for a number of reasons. First, saws are cutting thin-walled tubing, grooving, forming, and “gang” ground with side clearance. Clearance reduces the friction sawing. Irregular shapes such as hex, square, extruded, or between the workpiece and the cutter. Second, cutting with a pinion stock usually present a problem for a single point rotating circular saw is an “interrupted” cut, since each tooth tool due to the interrupted nature of the cut. Rotary sawing, cuts for only a brief moment. Third, as a single saw tooth makes however, is an interrupted cut anyway. Non-round bar stock a cut, the chip (and heat) is immediately removed from the cut- is not an additional challenge for those using rotary sawing ter by the strong coolant flow and the centrifugal force of the for cutoff. Exotic materials (hard rubber, plastic, teflon, etc.) rotating saw. Finally, each cutting edge is removing only a small and thin-walled tubing are often difficult to cut with a single amount of material, keeping the chip load low. point tool due to cutter and workpiece deflection, resulting What benefit is it to have no heat buildup? The lack of heat in part surfaces that are not square. Again, because of the low buildup allows the circular saw blade to be used more aggres- chip load while rotary sawing, cutter and workpiece deflec- sively than a single point tool. Feed rates can be increased from tion are eliminated. Part surfaces remain square and flat one and a half to four times that of single point tooling. within 0.002”—even when cutting these difficult materials. Increased feed rates reduce the cutoff time and, therefore, Rotary sawing is not limited to parting off. It can also be increase the number of parts cut per hour. Less heat buildup used for grooving and forming applications. Of course, when reduces the stress to the saw and material. Tool thickness can be grooving and forming with a circular saw, the profile of the reduced; the common saw thickness is 0.045”, which is approxi- saw must match the profile of the resultant part. When mately one third the thickness required for a single point tool. grooving and forming with a saw, the application affords the Tool life is longer, since a saw lasts two to 10 times longer per same technical advantages as cutting off with a saw. grind than a single point tool. These application improvements As an example, deep grooving is a great application for using reduce the time needed to cut parts and the costs associated a saw rather than a single point tool. Due to the low chip load with raw material, tooling, and tool maintenance. grooves stay square to the part, and thin walls between multiple Another constant struggle for machinists is the chip. The grooves do not deflect. Coolant delivery is improved when saw- resulting sharp, stringy, coiled chips of single point tooling ing deep grooves because the chips are immediately ejected, are especially problematic. The chips can have a tendency to allowing coolant to easily flow into the grooves. Grooving and get caught up in the workpiece or the tool. If dragged across cutting off can often be done at the same time by mounting the workpiece, chips may leave undesirable markings on the multiple saws onto the same arbor. The saws must be spaced part surface. The chips are cumbersome to remove, transport, appropriately by using spacers ground to the needed thickness. and store. Chip disposal is also time consuming and haz- Usually the setup is such that the first part is being cut off while ardous. Use a rotating circular saw and these problems the next part is being grooved. If a part has multiple grooves, immediately disappear. As mentioned, saw thickness is nar- additional saws can often be mounted onto the same arbor.

gearsolutionsonline.com • OCTOBER 2004 • GEAR SOLUTIONS 37 A “gang” saw arrangement is also possible for combined form- adapted to fit other turning machines and custom machines. ing and cutoff, or for multiple cutoffs. The negligible saw and part As mentioned earlier, if the host machine has live tooling deflection minimize the problems usually encountered when capability, an attachment will probably not be needed. attempting single point gang cutoff since the saws themselves act The sawing attachment and saw must be positioned perpendic- as guides to eject the cut part. Some saw users cut off as many as ularly to the workpiece, just as with single point tooling. Similarly, five or six parts at a time. Of course, saw configuration tolerances the centerline of the saw and the centerline of the workpiece are more critical when performing multiple cuts simultaneously. should be the same, although cutting on center is not as critical Much time has been—and is still being—spent on improv- with RSC. The cam (stroke) should be set to the depth of the cut ing the performance of single point tooling. Understanding plus 0.05”. The saw must not engage the workpiece in “high.” how to apply rotary sawing is no more complicated than ini- The circular saw can rotate in either direction. The most tially learning to apply single point tooling. However, a little desirable cutting dynamics are achieved in an “opposed” cut in training and effort toward the use of RSC will virtually assure which the saw and the workpiece are rotating in opposite superior results to those of single point tooling. directions at the point of their intersection. During a “climb” cut, both saw and workpiece rotate in the same direction at the point of intersection. Because an opposed cut delivers better RSC Setup cutting conditions, a climb cut is only recommended when As with single point tooling, RSC setup is application specific. cutting high carbon materials with high speed steel saws, or if The following discussion is a general starting point, which must the parts cannot be easily ejected during an opposed cut. then be refined based on the host machine, part configuration, Speeds and feeds are faster when cutting with a saw. Initially, part material, and part finish specifications. set the feed rate at double that of the single point tool rate. RSC utilizes a self-contained motorized attachment, which From there, rates can be adjusted higher until cutting results drives the circular saw. This setup mounts in the standard cut- start to deteriorate. Feed rates can be as much as 400 percent off position of the host machine, replacing conventional cutoff higher than single point tooling. Depending on the applica- tooling. The attachment is wired directly into the host tion, workpiece rpm is usually the same or slightly higher than machine, so the saw is switched on and off with the main with single point tooling. Set the saw speed to 150 to 350 rpm spindle of the host machine. Common host machines include higher than the workpiece. Feeds and speeds can be tweaked Acme-Gridley, New Britain, Conomatic, Davenport, Wickman, depending on cutting objectives (for example, parts per hour Gildemeister, Schuette, Warner & Swasey, Brown & Sharpe, versus part surface specifications) and tool life. Traub, and Index screw machines, as well as Bardons & Oliver Proper coolant type and coolant flow are critical, and the and Modern cutoff machines. The attachment can also be lubricating qualities of the coolant are more important than

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38 GEAR SOLUTIONS • OCTOBER 2004 • gearsolutionsonline.com the cooling qualities. When using high speed steel saws to cut the equipment, and tool life is five to 10 times better than that ferrous metals, it is necessary to use an oil coolant with a of high speed steel tooling. Heat sensitive materials or part heavy concentration of active sulfur. Active sulfur prevents geometries also require the use of carbide saws. galling at low cutting temperatures (under 350° F). Water A good starting point for saw thickness is one half the solulable coolant can be used with carbide saws, or when cut- thickness of the single point tool (often one third the thick- ting aluminum or brass parts. Coolant flow must be strong ness is enough). Aggressive cutting, deep cuts, and larger diam- and directed to the point where the saw enters the material. eter materials might require a thicker saw. For softer materials, The coolant flow must also be distributed equally to both smaller diameters, and thin-walled materials, narrower saws sides of the saw to promote even saw wear and to easily flush are used. The goal is to use the thinnest saw blade possible. chips from the workpiece as the saw rotates through the work. The distance to the cut, the depth of the cut, the configura- Changing saws is easy and takes only a few minutes. The tion of the tooling zone, and other attachments determine operator needs to make sure that the saw is securely clamped, the diameter of the saw. Saws for rotary sawing range from 2- is running in the proper direction, is running true, and that all 1/2” to 6” in diameter—the most common is 4”. Use the fol- arbor and support spacers are in good condition. Adjustments lowing formula to calculate the saw diameter. are rarely necessary because height settings repeat every time. Location settings may need occasional adjustment, but only Diameter = 2(distance from center of saw arbor to outside of attach- to maintain the tightest length tolerances. ment+depth of cut+tooling clearance needed for attachment+approach+breakthrough+0.025” minimum per saw when gang cutting) + 2(regrind stock, which is application specific) Saw Blade Configuration To utilize RSC to its fullest potential, proper saw configura- The number of teeth on a saw requires careful consideration is vital. Decisions on several items must be made, tion. A coarser tooth configuration should be used when the including saw material, saw diameter, saw thickness, number workpiece diameter is 1.5” or larger, when the workpiece has of teeth, tooth angle, rake angle, and surface treatment. a hole, when doing deep cuts, or when feed rates are over Circular saws for rotary sawing are commonly available in 0.003” i.p.r. As an example, a 4” diameter saw with 90 teeth two materials: solid carbide and high speed steel. S.f.m. of the (seven teeth per inch, 0.140” tooth gap) is considered coarse. job will usually determine which is to be used (carbide surface A finer tooth configuration is used for small diameters (up to feet rates require solid carbide saws). Carbide saws also cut 1” diameter), cutting to center, thin-walled tubing, better fin- more cleanly, resulting in better surface finishes and less burr ishes, and feed rates up to 0.003” i.p.r. or reduced nib. Cuts with carbide saws are less demanding on contined on page 46 >>

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gearsolutionsonline.com • OCTOBER 2004 • GEAR SOLUTIONS 39

MACHINERYMACHINERY

PFAUTER #PE-125H, 6-Axis, 5" Diam., 8.5 DP, 9.5" Max Swing, KASHIFUJI #KS-14, 14” Dia, Crowning, Auto Cycle, 4 DP REF#104 1988 REF#106 PFAUTER # P-400, 16” Dia, Vertical Universal, High Tailstock featuredSUPPLIERS: PFAUTER #PE-150, 6-Axis CNC, 6” Diam., 5 DP, 6” Face, Fanuc REF#104 18MI REF#106 PFAUTER #P-400H, 20” Dia x 160” Face Horiz, Crowning, 2-Cut, Alpha Gear & Machine, Inc. — Ref #100 PFAUTER #PE-500, 6-Axis CNC Gear Hobber, 13.78" Diam., 3 DP Sgl Index, ‘76 REF#104 Phone: 519-650-0943 •Fax #:519-650-7457 REF#106 PFAUTER #P-630, 24” Dia, Diff, Infeed, New ’67 REF#104 Email: [email protected] SYKES #H160, 4-Axis CNC Hobber, 6” Diam., All the Features, LIEBHERR #L-652, 24” Dia, Diff, Infeed, Crowning, 2-Cut, Yr ’76 1993 REF#106 REF#104 C-B Gear and Machine — Ref #101 BORAS Helical Gear Hobber REF#101 BARBER-COLMAN #25-30, 25” Dia, 30” Face Width, 2.5 DP REF#104 PFAUTER #PE-150, 6” Dia, 6-Axis CNC, New ‘86 REF#104 PGM-STAEHELY #SH-651, 25.5” Dia, Univ Hobhd, Yr ‘82 REF#104 Phone: 281-449-0777 • Fax #:281-590-9127 LIEBHERR #LC-152, 6”/8” Dia, 7-Axis CNC w/Automation, New LIEBHERR #L-901, 36” Dia, Crowning, Auto-2-Cut, Diff, Yr ’74 Email: [email protected] ’88 REF#104 REF#104 PFAUTER #P-800, 36” Dia, 6-Axis, CNC Universal, New ‘98 REF#104 G&E #48HWD, 48” Dia, Worm Driven Hobhead REF#104 Website: www.cbgear.com LIEBHERR #L-1801, 72” Dia, 6-Axis CNC Universal REF#104 G&E #48HWD, 48” Dia, Worm Driven Hobhead, Yr ‘72 REF#104 G&E #96H, 100” Dia, .75 DP, CNC Universal REF#104 G&E #72HWD, 72” Dia, 1.25 DP, Diff, Infeed, Sgl-Index REF#104 CNC Machinery Sales, Inc. — Ref #102 LIEBHERR #L-3002, 138” Dia, 4-Axis CNC Universal, New ‘84/04 G&E #96H, 100” Dia, 1 DP, Crowning, New ’72 REF#104 Phone: 602-244-1507 • Fax: 602-244-1567 REF#104 BARBER-COLMAN 2 1/2 -4, S/N 119, ’62 Hi-Production Spur Email: [email protected] GEAR HOBBERS/CUTTERS Gear REF#107 BARBER-COLMAN 6-10 SYKES, Triple Thrd w/Lever Operated Website: www.cncmach.com BARBER-COLMAN #2.5-4, 2.5” Diam., 2.25” Face, Precision Collet Assy REF#107 Machine REF#106 BARBER-COLMAN 6-10 B&C Ltd, S/N 8079, Triple Thrd REF#107 Midwest Gear Corporation — Ref #103 BARBER-COLMAN #14-15, 14” Diam., 15” Face, 1 to 4 Start BARBER-COLMAN 6-10, S/N 4626, ’57 Triple Thrd 3” Hob Slide Phone: 330-425-4419 • Fax: 330-425-8600 worm, Several REF#106 REF#107 BARBER-COLMAN #14-30, 14” Axis, 30” Diam., 3.5 DP, 1967 REF#106 BARBER-COLMAN 6-10, S/N 4659R, ’56 Triple Thrd Adj Ctr Assy Email: [email protected] BARBER-COLMAN #16-16, Multi-Cycle, Dual Thread Worm, REF#107 Website: www.mwgear.com Downfeed REF#106 BARBER-COLMAN 6-10, S/N 4665, ’57 Fine Pitch Prec Triple BARBER-COLMAN #16-36, 24” Diam., C-Frame Style, 4 1/8” Thrd REF#107 Mohawk Machinery, Inc. — Ref #104 Bore REF#106 BARBER-COLMAN 6-10, S/N 4701, ’58 Triple Thrd w/Power Phone: 800-543-7696 • Fax: 513-771-5120 BARBER-COLMAN #16-56, 16” Diam., 56” Face, Differential REF#106 Down Feed REF#107 BARBER-COLMAN #22-15, 22” Diam., 14” Face, Differential REF#106 BARBER-COLMAN 6-10 M/C, S/N 4755, ’59 Triple Thrd w/MC Email: [email protected] BARBER-COLMAN #3 (6-10), Single & Triple Tread Worm Ref # Conversion REF#107 Website: www.mohawkmachinery.com Several REF#106 BARBER-COLMAN 6-10 Multicycle, S/N 4778R87, ’60 (’87 BARBER-COLMAN #6-16, 6 Start Worm, Downfeed, Hyd. Rebuild), Sgl Thrd Hi-Spd REF#107 New England Gear — Ref #105 Clamping REF#106 BARBER-COLMAN 6-10 M/C, S/N 4913, ’63 Triple Thrd w/90 G & E #24H Universal Head, Infeed, Tailstock, Differential, 1950’s Deg Hob Slide REF#107 Phone: 860-223-7778 • Fax #:860-223-7776 REF#106 BARBER-COLMAN 6-10 Multicycle, S/N 5055, ’66 Triple Thrd, Email: [email protected] G & E #36HWD, Differential, Excellent Condition, New 1940’s REF#106 800 RPM REF#107 G & E #48HWD, Differential, Excellent Condition, New 1950’s REF#106 BARBER-COLMAN 6-10, S/N 5141, ’67 Triple Thrd w/Prec Hob R. P. Machine Enterprises, Inc. — Ref #106 G & E #72H, 72" Diam., 1.5 DP, 24" Face, Diff., Infeed REF#106 Shift REF#107 G & E #96H, High Stanchion, Differential, Infeed REF#106 BARBER-COLMAN 6-10 Multicycle, S/N 5148, ’68 Triple Thrd, Phone: 704-872-8888 • Fax #:704-872-5777 HAMAI #120, 4.8” Diam., 4” Face, 12 DP, ‘70 REF#106 800 RPM REF#107 Email: [email protected] KOEPFER #135, Horiz., Loader, 3” Diam., 3” Face, 25 DP, 1960 BARBER-COLMAN 6-10 Multicycle, S/N 5259, ’75 Triple Thrd Website: www.rpmachine.com REF#106 w/Auto Hob Shift REF#107 LIEBHEER #L-301, 12” Diam, 9’ Face, 4 DP, 1974 REF#106 BARBER-COLMAN 6-10, S/N 5353, ’77 Triple Thrd w/3” Hob Repair Parts, Inc. — Ref #107 LIEBHEER #L-400, 16” Diam, 10’ Face, 3 DP, High Helix, Slide, 800 RPM REF#107 Crowning, 1968 REF#106 BARBER-COLMAN 6-10, S/N 5394, ’81 Fine Pitch Triple Thrd Phone: 815-968-4499 • Fax #:815-968-4694 LIEBHEER #L-401, 16” Diam, 8’ Face, 3 DP, 1970’s REF#106 w/Dwell & Hob Rev REF#107 Email: [email protected] LIEBHERR #L-402, 16” Capacity, 2-Cut Cycle, Crowning, 1977 REF#106 BARBER-COLMAN 6-16 M/C, S/N 5238, ’70 Triple Thrd, Recon Website: www.repair-parts-inc.com LIEBHERR #L-652, 25" Diam. Cap., 19.7" Face, 2 DP, Well- ‘02 REF#107 Equipped REF#106 BARBER-COLMAN 6-10, S/N 5407, ’82 Auto w/PLC Control REF#107 LIEBHERR #L-901, 35" Diam., 2.5 DP, 2-Cut Cycle, Univ. Hob Contact Gear Solutions at 800-366-2185 BARBER-COLMAN DHM, S/N 105, ’42 Double Thrd REF#107 Head REF#106 BARBER-COLMAN 14-15, S/N 635R, ’53 Dbl Thrd, Fact Reb REF#107 to list your Machines, Services and Tooling! LIEBHERR #L-902, 36" Diam., 25" Face, 2 DP, Crowning, 1978 BARBER-COLMAN 14-15, S/N 745, ’55 Dbl Thrd w/Dwell REF#107 REF#106 BARBER-COLMAN 14-15 Dual Fd, S/N 938, ’62 Dbl Thrd, Comp NIHON KIKAI #NDH-1200, 49" Diam., 2.5 DP, 36-180 RPM, GEAR ACCESSORIES, PARTS & TOOLING Recon REF#107 Crowning REF#106 BARBER-COLMAN 14-15, S/N 1055, ’65 Dbl Thrd w/New Hyd FELLOWS Model #10-4/10-2, All Parts Available REF#105 RPM #AD-616, 6” Diam., 16” Face, 16 DP, (3) Thread, NEW REF#106 Sys REF#107 Tilt Tables for 10-2/10-4, Qty 2 REF#105 PFAUTER #P-400, 3 DP, 16" Diam., 11" Face, Auto-Cycle, 1965 BARBER-COLMAN 14-15, S/N 1131, ’66 Dbl Thrd w/Hyd Tailctr GEAR HOBBERS/CUTTERS CNC REF#106 REF#107 PFAUTER #P-630, 24” Capacity, 2-Cut Cycle, Crowning, 1978 BARBER-COLMAN 14-15 Dual Fd, S/N 1261, ’67 Dbl Thrd w/Hyd G & E #CNC Miller/Gasher #60S-2, 1 DP, 72” Diam., 38” Vert.,60 REF#106 Live Ctr REF#107 HP, 1980 REF#106 PFAUTER #P-750R, 8" Diam. ROTORS, 35" FACE, 12", MINT!!, BARBER-COLMAN 14-15 Dbl Cut, S/N 1278, ’68 Dbl Thrd w/4- G & E #120H “CNC” Gasher/Hobber, Twin Stanchion, 1/2 DP, 42” 1982 REF#106 1/8” Bore REF#107 Face, 1994 REF#106 PFAUTER #P-900, 2 DP, 36” Diam., 15” Face, Tailstock,1960 REF#106 BARBER-COLMAN 14-30 Dual Fd, S/N 1371, ’71 4-Thrd w/Sizing GLEASON PHOENIX #125GH, 6-Axis CNC, 4.92" Diam., 7.8 DP REF#106 PFAUTER #P-2500, 100” Diam., 30” Face, 1.4 DP, Differential REF#106 Cycle REF#107 HAMAI 60H, CNC 4-Axis, 3.5" O.D., 9" Face, 12 DP, New: 1989 REF#106 WOLF #GH20-11, 20” Diam., 11” Face, 3.2 DP, 1998 REF#106 BARBER-COLMAN 22-15, S/N 923, ’62 Dbl Thrd, Dbl Cut REF#107 LIEBHERR #LC-255 “CNC”,6-Axis, 10” Diam., 10” Face, 4 DP,1987 WOLF #GH32-11, 32” Diam., 11” Face, 2.5 DP, 1998 REF#106 BARBER-COLMAN 16-11, S/N 184, ’50 Dbl Thrd w/Vert DRO REF#106 TOS #OFA32A, Auto, New, 12”x10”, Yr ‘86 REF#100 REF#107 LIEBHERR #LC-502 “CNC”,6-Axis, 20” Diam., 16” Face, 2 DP,1987 TOS #OFA71A, Auto, 29”x18”, Yr ’81 REF#100 BARBER-COLMAN AHM, S/N 1896, ’42 Sgl Thrd w/3 Jaw Chuck REF#106 LIEBHERR #L650 REF#100 REF#107 LIEBHERR #L-1202 6-Axis CNC, 49” Diam., 24” Face, 1.2 DP, LIEBHERR #ET-1202, 48” Dia, 4-Axis CNC Ext Miller/Gasher REF#104 BARBER-COLMAN 16-16, S/N 2745, ’51 Sgl Thrd w/90 Deg Hd 1978 REF#106 LIEBHERR ET-1500, 60”Dia, Internal Spur Miller/Gasher REF#104 REF#107 MITSUBISHI #GA-40, 5-Axis, 16” Diam., 10” Face, w/Fanuc,1986 KOEPFER #150, 6” Dia, Refurbished w/Accessories REF#104 BARBER-COLMAN 16-16, S/N 3171, ’53 Dbl Thrd, Spanish REF#106 KOPEFER #151, 6” Dia, Refurbished w/Accessories REF#104 Nameplates REF#107 PFAUTER #P-125H, 6-Axis, 32” Diam., 3” Face, 1981 REF#106 KOPEFER # 170, 5.1” Dia, Refurbished, w/Accessories REF#104 BARBER-COLMAN 16-16, S/N 3580, ’59 Dbl Thrd w/Diff & Auto PFAUTER #P-250H, 6-Axis, 11.81” Diam., Fanuc O Control, NEW PFAUTER #RS00S, 8”/10” Dia, 6 DP, Diff REF#104 Hobshift REF#107 1985 REF#106 LIEBHERR #L-200, 10” Dia, Hvy-Duty Hi-Speed, Yr ‘79 REF#104 BARBER-COLMAN 16-16 Multicycle, S/N 3641, ’60 Dbl Thrd PFAUTER #PE-300, 6-Axis, 12” Diam., A/B 8600 Control, NEW LIEBHERR #L-301, 12” Dia, 2-Cut, Crowning REF#104 w/Diff REF#107 1987 REF#106 CLEVELAND #CR-300, 12” Dia, Crowning, 2-Cut, New REF#104 BARBER-COLMAN 16-16, S/N 3660, ’57 Sgl Thrd REF#107

gearsolutionsonline.com • OCTOBER 2004 • GEAR SOLUTIONS 41 BARBER-COLMAN 16-16, S/N 4136, Dbl Thrd, “C” Style End FELLOWS #4A & 4AGS, 6” Diam., 2” Face, 4DP, 1968, Ref.# GLEASON #3”, 4.45” Dia, 2-Tool w/Segments & Gears REF#104 Brace w/Diff REF#107 Several REF#106 GLEASON #710, 10” Dia, Coniflex REF#104 BARBER-COLMAN 16-16 Multicycle, S/N 4170, Dbl Thrd w/Jump FELLOWS #61, #6A, #61A, #645A, From 18”-35” Diam. 0-12” GLEASON #104, 8.5” Dia Coniflex REF#104 Cut Cycle “C” Style REF#107 Risers REF#106 GLEASON #14, 24” Dia, Coniflex w/gauges, gears REF#104 BARBER-COLMAN 16-16, S/N 4473, ’73 4-Thrd w/Workclamp FELLOWS #7, #7A, #715 Etc., 7” Diam. 0-12” Risers, Several GEAR GENERATORS, SPIRAL BEVEL (HYPOID) Cyl “C” Style REF#107 Avail. REF#106 BARBER-COLMAN 16-16 Multicycle, S/N 4520, ’75 Dbl Thrd FELLOWS #8AGS Vertical Gear Shaper, 8” Diameter, 2” Face, 6-7 CNC 116 Gear Generator or Hypoid Rougher w/Fanuc 161-MA w/Gooseneck Slide REF#107 DP REF#106 Control REF#102 BARBER-COLMAN 16-16 Multicycle, S/N 4631, ’79 “C” Style End FELLOWS #10-2, 10” Diam., 4” Face, 4 DP REF#106 GEAR GENERATORS, HERRINGBONE Brace, 4W Adj Ctr REF#107 FELLOWS #10-4, 10” Diam., 4” Face, 4DP REF#106 SYKES Model #1A, 12” Diameter, 30˚ Guide and Spur Guide REF#106 BARBER-COLMAN AHM (36”), S/N 1152, ’42 Dbl Thrd REF#107 FELLOWS #18-5, 18” Diam., 5” Face, 3 DP, 1974 REF#106 FARREL-SYKES #2A Herringbone Gear Shaper REF#101 BARBER-COLMAN 16-36, S/N 4090, ’66 Dbl Thrd, “C” Style End FELLOWS #20-4, 20” Diam., 4” Face, 4 DP, 1970’s REF#106 Brace REF#107 FELLOWS #36-6, 36” Diam., 6” Face, 3 DP, 1951-1955 REF#106 GEAR GRINDERS CNC BARBER-COLMAN 16-36 Multicycle, S/N 4232, ’68 Dbl Thrd “C” FELLOWS #36-8, 36” Diam., 8” Face, 3DP, 1953 REF#106 OERLIKON/OPAL #50 CNC Form Grinder, 20.5" Diam., 24.8" Face, Style End Brace w/Diff REF#107 FELLOWS #48-6 Int./Ext. Gear Shaper, 28-72" Diam., 6.25" 1998 REF#106 BARBER-COLMAN 16-56, S/N 3136R84, ’53 (Reb ’84), Dbl Thrd Stroke REF#106 REISHAUER #RZ-301S CNC, 12" Diam., 4 DP, DIN 5 Quality, REF#107 FELLOWS #50-12 Hydrostroke, Gear Shaper, 50” Diam., 12” 1989 REF#106 BARBER-COLMAN 10-20, S/N 6700045890, ’76 Dbl Thrd w/2 Face REF#106 GLEASON #120 Curvic Grinder REF#102 Cut Cycle REF#107 FELLOWS #120-8, 8” Stroke, Spur Guide, Rebuilt 1988, New KAPP #VAS-531, 20” Dia, CNC Spur/Helical, New ‘91 REF#104 HOEFLER #H-650/800, 36”Dia, CNC w/On-Board Inspection, New GEAR PINION HOBBERS & SPLINE MILLERS Electrics REF#106 FELLOWS #200, 8” Stroke, 200” Diam. Spur, Exc. Cond 1 DP, ‘98 REF#104 LEES BRADNER #SH, 8” Diam., 54” Face, 4 DP, 1950 REF#106 Rebuilt 1988 REF#106 GLEASON # 130, 36” Max Dia, CNC Curvic Cplg, Comp Reb REF#104 HURTH #KF-32A 15” Diam., 59” Face, 1967 REF#106 FELLOWS #Horiz. Z Shaper, 6” Stroke, 17” Bore in Table, New GEAR GRINDERS NEWARK Horiz.Pinion Hob, 18”Diam., 112” Face, 5 DP REF#106 1950’s REF#106 FELLOWS-REISHAUER #12, 12" O.D., 6-3/4" Face, Dresser, Gears WANDERER #31M, 12” Diam., 118” Length, Hob Head Equipped MAAG #SH-75C, Disc Control, 9” Stroke, Auto Stop, Exc., 1965 REF#106 REF#106 REF#106 HOFLER H2500/1200, 98” Diam., 47” Face, 8DP, 1974, ISO 3-4 GEAR HOB & CUTTER SHARPENERS (incl CNC) MAAG #SH-100K, Disc Control, 47” Diam., 12” Face, 1.7 DP, Quality REF#106 1960’s REF#106 ARTER #A-12, 12” Rotary Surface Grinder for Sharpening REISHAUER ZA, Gear Grinder, 13" Diam, 6" Face, Strait & Helix, MAAG #SH-180/300, Ext. Generating/Int. Gashing Heads, New REF#106 Sharper Cutters, REF#106 1960’s REF#106 BARBER- COLMAN #6-5, 6" Diam., 5" Length, Manual Dresser, REISHAUER #RZ-300E, 12” Diam., 5 DP, 1986, REF#106 MAAG #SH-1200 Heavy Duty Gear Cutter, 472" Diam., 112" Face, REISHAUER #RZ-301S, 12” Diam., 4 DP, w/ Stock Dividing, 1957 REF#106 1980 REF#106 BARBER-COLMAN 10-12, 10" Diam., 12" Length, Spark Out REF#106 1989 REF#106 TOS #OHA50A, Auto, 20” x 5”, Yr ’86 Low Hours REF#100 REISHAUER #AZA & #AZA-K, 11” Diam., 3 DP, 7” Face, Excellent HEALD #22 Rotary, 13” Diam., 12” Chuck, REF#106 MAAG #SH75C, Sub Table, Steady, Nice REF#100 KAPP #AS204GT, 10” Diam., Wet Grinding, CBN Wheels, 1982 Condition REF#106 MAAG #SH75 w/JV75 REF#100 REISHAUER ZB Gear Grinder, 27 5” Max Diam., 11” Face, Good REF#106 FELLOWS #6 Gear Shaper REF#102 KLINGEINBERG #SNC-30, “CNC” 12” Diam., 18” Length, CBN or Condition, 1970 REF#106 FELLOWS #3, 3” Dia, Fine Pitch, w/Change Gears REF#104 RED RING #SF-500 Int/Ext., 26” Diam., 30” Face, 2 DP, 1988 REF#106 Std. Wheels REF#106 FELLOWS #725, 7” Dia, 1.5” Face REF#104 MAAG #SD-36-X, 14.2" Diam., 2.1 Max DP, Like New!!, 1989 REF#106 KLINGELNBERG #AGW-30A, 11” Diam., 16” Part Length, FELLOWS #8AGS, 8” Dia, 2” Face REF#104 MAAG 72” Gear Grinder REF#101 Straight & Spiral Gash REF#106 FELLOWS #10-2, 10” Dia, 2” Face REF#104 MAAG 32" Gear Grinder REF#101 KLINGELNBERG #AGW-231, Automatic Hob Sharpener, 10" FELLOWS #10-4, 10” Dia, 4”Face REF#104 STANKO 24" Gear Grinder, New REF#101 Diam., 1980 REF#106 FELLOWS #10-2, (10” Dia), 2” Face REF#105 NILES 800 Millimeter Gear Grinder REF#101 MAAG #WS, 2 Rack Cutter Sharpener REF#100 FELLOWS #10-4, (10” Dia), 4” Face REF#105 GLEASON #120 Curvic Grinder REF#102 BARBER-COLMAN 10x10 Hob Sharpeners, Qty 2 REF#101 BARBER-COLMAN 4x4 Hob Sharpeners, Qty 2 REF#101 GEAR DEBURRING/CHAMFERING/POINTING GEAR RACK MILLERS/SHAPERS BARBER-COLMAN #2 1/2-2, 2.5” Dia, Straight Flute Hobs CROSS #75 Gear Tooth Chamferer, 10” Diam., 10” Face, 1952 FELLOWS #3X36 Rack Shaper, 3” Face, 36” Face, 4 DP, Good REF#104 REF#106 Cond., 1960 REF#106 BARBER-COLMAN #3-4/4, Index Plates REF#104 HURTH #ZK-7, 11” Max Diam., Twin Spindle Gear Chamferer REF#106 FELLOWS #61A Gear Shaper w/48” Rack Att., 8” Riser, Rebuilt in MIKRON #A62, 6” Dia, Auto Dressing, Coolant REF#104 HURTH #SRS400, Gear Shaver, Grinder & Sharpener, 1.57” 1990’s REF#106 KLINGELNBERG #AGW-230, 10” Dia, Index Plates REF#104 Diam. REF#106 MIKRON #134 Rack Shaper, 17.4" Length, 1.1" Width, 16.9 DP REF#106 KLINGELNBERG #SNC-30, 12” Dia, CNC Hob Sharp, New ’84 REF#104 RED RING #GCU-12, Gear Shaver, 12” Diam., Several REF#106 SYKES 1800R Vertical Rack Shaper, 72" Cut Length, 4DP, 4" BARBER-COLMAN 2 1/2 -2, S/N 16, ’66 Wet w/Auto Feed RED RING #GCY-18, Gear Honing Machine, 18” Diam., 6” Stroke Stroke, 1980 REF#106 REF#107 REF#106 GEAR THREAD & WORM, MILLERS/GRINDERS BARBER-COLMAN 6-5, S/N 110R, ’55 Wet w/Auto Dress & Sparkout RED RING #GCX-24, 3”-24” Pitch Diam. Crowning, tailstock, REF#107 taper Att., REF#106 EXCELLO #39A, 9.5” Diam., 5” Length, ‘60’s REF#106 BARBER-COLMAN 6-5, S/N 396, ’66 Wet w/Auto Dress & Sparkout REDIN # 6, 6" Diam., 3" Face, .33 to 14 RPM, 4" Internal REF#106 WMW HECKERT #ZFWVG, 10” Diam., 49” Length, 4, 1999 REF#106 REF#107 REDIN #18, 28” Diam., 2, 3, 4 Spindle, Deburrer/Chamfer, WMW HECKERT #ZFWG 250 X 2000, 19.6” over bed, 19.6” BARBER-COLMAN 6-5, S/N 433, ’69 Wet w/Auto Dress & Sparkout 1990’s-2000, Several REF#106 78.7” Hob length REF#106 REF#107 REDIN #24, 30” Diam., 16” Face, 2 Post, Deburrer/Chamfer, JONES & LAMPSON 12x45, 12” Diam., 45” Length REF#106 BARBER-COLMAN 10-12, S/N 643R83, Wet w/Auto Dress, PC 1990’s (2) Available REF#106 LEES BRADNER #HT 12"x 36" Thread Mill, 12" Dia.,36"Length REF#106 Control, Fact Reb ‘83 REF#107 SAMPUTENSILI #SCT-3, Chamf/Deburrer, 14” Diam., 5” Face, MIKRON #106-02, 1.5” Diam, 3-6” Length, Single Form Worm Cutter REF#106 GEAR LAPPERS 1982 REF#106 SAMPUTENSILI #SM2TA Gear Chamfering Machine, 10” Max. REISHAUER #UL-900, 9” Diam., 18” Grinding Length, 1980’s REF#106 GLEASON #503, 10.5” Dia, Hypoid, 90-Degree REF#104 Diam., (3) New 1995 REF#106 REISHAUER #US, 10” Diam., 36” Grinding Length,46” B-C, 1980 GEAR SHAPERS CNC CROSS #75, 10” Dia REF#104 REF#106 WANDERER #31L x 3000, 8” Diam., 120” Length, 1960’s REF#106 CROSS #65, 10” Dia, 9” Face, 4 DP REF#104 FELLOWS #10-2 & 10-4, 1 to 4-Axis “CNC”, 10” Diam., 2”-4” GEAR TESTERS/CHECKERS (incl CNC) Face, Rebuilt REF#106 REDIN #24, 28” Dia CNC Twin Spindle Deburring Mach, Yr ’90 FELLOWS #10-4 One-Axis CNC (A/B), 10" Diam., 4" Face, 4 DP REF#104 Please Check Our Website to View the Gear Testers and REF#106 REDIN #18, 20” Dia Twin Spindle Deburring Mach REF#104 Recorders in Our Inventory REF#106 FELLOWS #20-4, 4-Axis, 20” Int./Ext., Diam., 4” Face, New GEAR HONERS GLEASON 13 Hypoid Tester (2) REF#102 1970/2003 REF#106 FASSLER #K-400 Internal Gear Hone, 12.6” Diameter, 12” GLEASON 13, Universal Angular Bevel Tester REF#104 FELLOWS #20-8 "Hydrostroke" 6-Axis CNC, 20" Diam., 8" Face, 3 Stroke, NUM 1080 Control REF#106 GLEASON #15, 15” Dia, Blank Checking Device REF#104 DP REF#106 GLEASON #D-15S, Spiral Bevel Cutter Inspection Device REF#104 FELLOWS #FS-400-125, 5-Axis CNC,16"Diam, 4 DP, NEW FANUC GEAR SHAVERS FELLOWS #4RL, 4” Dia, Comp Roll Checker REF#104 16MI REF#106 RED RING Shaver 12" REF#101 FELLOWS #12M, 12” Dia, Involute REF#104 FELLOWS #FS-630-200, 6-Axis, 24” Diam., 8” Face, 3 DP, 1995 RED RING #GCY-12, 12” Dia, 9” Cutter-Head REF#104 MISCELLANEOUS REF#106 RED RING #GCU-12”, 12” Dia, 9” Cutter-Head REF#104 LIEBHERR #WS-1, 4-Axis CNC, 8" OD, 2" Stroke, Fanuc 18MI REF#106 RED RING #GCU-18, 18” Dia, Crowning REF#104 MAS VO50 Radial Drill, 63”x34, 2500 RPM REF#100 LORENZ # LS-154, 4-Axis CNC, 6” OD, 1.7” Stroke, Fanuc RED RING #GCJ-36/60, 60” Dia, 12” Cutter-Head REF#104 TOS W100A Boring Mill, 15050, 63”x49”x44”, Tailstock, DRO REF#100 F15MB, 1993 REF#106 CINCINNATI Avenger CNC Turning Center, Model #200MS, S/N LORENZ #LS-424 CNC Gear Shaper, 16.5" Max Diam., 5.4" GEAR GENERATORS, STRAIGHT BEVEL 3650-AMS-94-0243 w/850SX Control, 12 Position Turret, 8” Stroke, 1990 REF#106 GLEASON #12, Str. Bev. Gear Generator, 12” Cone, 3.5 Face, Chuck, 6” Chuck REF#102 FARREL-SYKES #2A Herringbone Gear Shaper REF#101 1950’s REF#106 CINCINNATI Avenger CNC Turning Center, Model #250MT, S/N FELLOWS Type 6 Gear Shapers REF#101 GLEASON #14 “Coniflex” Str. Bev. Gear Generator, 12” Max. Cone 3650-BMT-94-0218 w/850SX Control, 10” Chuck REF#102 FELLOWS #10-4/10-2, Qty 150 REF#105 Dist., 3.5” Face REF#106 LODGE & SHIPLEY Profiturn 50 CNC Lathe, 176” Centers, 27” HYDROSTROKE #50-8, Qty 2 REF#105 GLEASON #104 "Coniflex" Str. Bev. Gear Generator,4.5” Max. Cone Swing, 39” Over Bed, 7” Hole thru Spindle, Reb ‘02 REF#102 HYDROSTROKE #20-8, Qty 5 REF#105 Dist. REF#106 HUFFMAN TRUMPF HP-105 CO1/2 CNC Laser System w/GE HYDROSTROKE #FS630-125, Qty 1 REF#105 GLEASON #114 “Coniflex” Str. Bev. Gear Generator, 7” Max. Cone 2000 Control REF#102 RIGID 5-Axis CNC Mill, 2-Spindle, Type NB125, Allen Bradley HYDROSTROKE #FS400-90, Qty 2 REF#105 Dist., 2.5” Face REF#106 FELLOWS #20-4, Qty 6 REF#105 Control REF#102 GLEASON #24A "Coniflex", 1.5 DP, 6" Face, 6" Work Spindle Bore HEALD 273A Internal Grinder REF#102 FELLOWS #48-8Z, Qty 1 REF#105 REF#106 36” Shapers, 14” Throat Risers, 53” of Swing, Qty 3 REF#105 MAZAK 24” x 120” Manual Engine Lathe REF#102 GLEASON #28, Hypoid Generator, 33” Diam., Max. DP 1.5 OKAMOTO ACC-124N, 12” x 24” Surface Grinder REF#102 GEAR SHAPERS REF#106 KENT KGS-63AD 12” x 24” Surface Grinder REF#102 GLEASON #37, 26” Cone, 10” Face REF#106 WARNER & SWAYSEY #4A M-3580 Turret Lathe, 28 1/2 Swing, FELLOWS #3-3 & #3-1, 3” Max. Diam., 1” Face, Pinion Supp., MIKRON #120.1 & 132.02, 1.6” Diam., 25 DP, 50’s-60’s High Precision REF#106 80” Centers, 12” Spindle Hole 50/25 Motors, 480/3 Phase, Year REF#106 1965 REF#103

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ABUNDANT MANUFACTURING, INC. Allen Adams Shaper Services, Inc. 325 NORTH MILLER AVE. • STATESVILLE, NC 28677 PHONE: (704) 871-9911 Servicing Fellows FAX: (704) 871-9961 Gear Shapers EMAIL: [email protected] On Site Service: Emergency & Scheduled WEBSITE: WWW.ABUNDANTMFG.COM Te chnical Support: Via Telephone. Fax or E-mail Tr aining: Operator, Set Up & Maintenance (Electrical & Mechanical) Preventive Maintenance plans: Customized to Your Needs Parts: New and/or Used Retrofits – Counters, Servo Controllers, or Single and Multiple Axis CNC Hydrostatic Guides: Repair Service or Purchase New

I am the former Service and Technical Support Manager for Fellows. Working with me are several former Fellows Service Engineers. Between us we have the knowledge and capability to support all modes of Fellows shapers from the oldest to the newest CNC and Hydrostroke GEAR GRINDING...... 27” DIAMETER machines. Please consider us for all of your Shaper needs. GEAR HOBBING ...... 84” DIAMETER 36” FACE Allen Adams GEAR SHAPING ...... 120” DIAMETER 8” FACE GEAR SHAVING...... 24” DIAMETER Telephone: 802-259-2937 Fax: 802-259-3937 ABUNDANT — GEARED TO SERVICE YOUR NEEDS! e-mail: [email protected]

Engranes SPIRAL BEVEL GEARS Industriales Rivera, S.A. de C.V. Due to customer demands, we have expanded our STRAIGHT BEVEL ability and added SPIRAL BEVELS to our capabilities. Our capacities are constantly expanding, so please forward your specific requirements for a prompt, competitive quotation.

SPIRAL BEVEL .25” to 33” Diameter 32 DP to 2 DP .5 Module to 12 Module

STRAIGHT BEVEL .25” to 36” Diameter 32 DP to 1.5 DP .5 Module to 16 Module

Manufacturing ALL TYPES of custom gears: Spiral Bevels, Straight Bevels, Spurs, Helicals, Worm and Worm Gears, Herringbones, Racks, Splines, Internal Gears, Sprockets, Ratchets Tooth Cutting, Grinding & Shaving services available.

Please fax your inquiries Quality Custom to Dennis Garthus at Poniente 128 # 389 • Col. Nueva Vallejo • 07750 – México City 708-652-1100 Gearing Since 1951 Phone: 011 (525) 55587-8266 • 011 (525) Fax: 5368-3432 [email protected] CIRCLE GEAR and MACHINE 1501 South 55th Ct. • Cicero, IL 60804 • Ph: 708-652-1000 • Fax: 708-652-1100 • circlegear.com

44 GEAR SOLUTIONS • OCTOBER 2004 • gearsolutionsonline.com FINEST LINE OF SWISS GEAR CUTTING TOOLS

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MINI-JOINT® COUPLING •Allows for radial, angular and lateral misalignment •Operating speeds to 30,000 RPM www.hanikcorp.com HANIK CORPORATION 271 E. BEINORIS DRIVE // WOOD DALE, IL 60191 118 Long Pond Road, Plymouth, MA 02360 PHONE 630-595-7333 // FAX 630-595-7343 Toll Free: (888) 309-0646 (508) 746-0200 FAX: (508) 746-6494 www.gtcfalcon.com

KA-WOOD GEAR & MACHINE COMPOSITE GEAR ROLLING INNOVATIVE 32500 Industrial Drive / Madison Heights, MI 48071 INSTRUMENTS (248) 585-8870 / Fax: (248) 585-3011 RACK & GEAR Email: [email protected] / www.kawoodgear.com COMPANY ITW MODEL 2275 Custom Manufactured GEARS & GEAR RACKS • LARGE STOCK, IMMEDIATE DELIVERY • PLAIN UNITS FOR STUB GEAR ARBORS • COLUMN OVERARM UNITS MANUFACTURING CAPABILITIES INCLUDE: Spur & Helical Gears • Spur & Helical Racks • Involute & Straight Sided Splines • Gear Grinding & Shaving • Sprockets & Timing Belt Pulleys • Broaching Keyways & Splines • Tooth Rounding & Chamfering • Manufacturing Gear Blanks

Various Rack Shapes, Sizes & Materials • Unique Tooth Configurations • Heat Treating • Complete Machining • Accuracy Tolerances up to AGMA Q12 • Spur, Helical, Relieved, Tapered, CrownedCrowned •• Breakdown Breakdown Service Service Available Available • Reverse• Reverse Engineering Engineering Capability Capability KING PRECISION TECHNOLOGIES, Inc. 2827-A Gray Fox Rd. • Monroe, NC 28110 797 EAGLE DRIVE • BENSENVILLE, IL 60106 Ph: 704.296.9100 • Fax: 704.296.5635 FELLOWS 70-15 GEAR SHAPER 105” Dia. • 70” Pitch Dia. • 15” Stroke Capacity Email: [email protected] 630-766-2652 • FAX 630-766-3245 • WWW.GEARACKS.COM SPECIALTY MACHINE — ONE OF ONLY A HANDFUL IN THE WORLD! GEAR TOOTH GEAR GRINDING SERVICES GRINDING SERVICES Gear cutting from raw material to finished parts Spur - Helical - Double Helical Capacity up to 60.5” O.D. , 1 D.P., 29” Stroke. All Ground tooth gears and ground gears certified up to AGMA Class 14+ on pinions to 1 D.P. and up Zeiss-Höfler 1602 CMM. Inventory of grinders to AGMA quality class 13 includes Höfler 800, Höfler 1253 Supra, Höfler 1500, two Höfler Nova CNC 1000s (Fully CNC with on-board CMM checker), and Höfler Rapid 1000 From 1” Diameter, 64 D.P. Form Grinder. to maximum sizes listed Max. Face Max. Size Max. Pitch Spur Gears 24” 92” P.D. 1 D.P. NON-METALLICS • LAMINATES/PLASTIC Helical Gears 24” 72” P.D. 1 D.P. PRECISION MACHINING • GENERAL FABRICATION Spur & Helical Gears, CERTIFIABLE QUALITY Crown Hobbed 22” 72” P.D. 1 D.P. We are committed to fabricating top-quality COMPETITIVE PRICING non-metallic parts, delivering those parts in a Kreiter Geartech Internal Gears & Splines 8” 100” P.D. 1-1/4 D.P. ON-TIME DELIVERY timely manner at the most competitive price, 2530 Garrow St. Houston, TX 77003 Ground Gears, Crowned or Straight 20.5” 72” P.D. 1 D.P. OUTSTANDING and to serve you in a friendly, courteous manner. Phone: 713-237-9793 Fax: 713-237-1209 Herringbone Gears, Center Grove 14” 36” P.D. 2 D.P. PRODUCTS & SERVICES [email protected] Contact: Mr. Willie Whittington WWW.MOOREADDISON.COM Email: [email protected] MOORE-ADDISON 2182 E. Aurora Rd., Twinsburgh, OH 44087 Visit our Website at www.kreiter-geartech.com Phone: (330) 425-4419 • Fax: (330) 425-8600 518 FACTORY ROAD • ADDISON, ILLINOIS 60101 www.mwgear.com • E-mail: [email protected] 630-543-6744 • FAX: 630-543-2805

gearsolutionsonline.com • OCTOBER 2004 • GEAR SOLUTIONS 45 << contined from 39 TABLE 1 CARBIDE SAW HIGH SPEED STEEL SAW 12L14, 1215, aluminum, brass No treatment LN (Liquid Nitride) or TiN 1010-1026, high carbon TiN (Titanium Nitride) or LN or TiN steel alloys, SS TiCN (Titanium Carbonitride) 52100 TiCN or TiAlN (Titanium N/A Aluminum Nitride) CNCCNC Spur/HelicalSpur/Helical GearGear RackRack MillingMilling && Grinding Grinding MachinesMachines

•• LongLong provenproven tracktrack recordrecord Tooth angles are the last consideration tooling, this “super tool” must not be •• HighHigh PowerPower •• HighHigh QualityQuality •• VariousVarious CuttingCutting FunctionsFunctions for saw geometry. Cutoff angles reduce overlooked. Cutting off is the one oper- [[variablevariable pitchpitch -- plungeplunge -- reliefrelief -- crown - taper - etc. ] burr or the nib, produce better surface ation common to all parts turned from Visit www.saikuni.co.jp finishes, and control ring problems. Use bar stock. Technical improvements in for more information the smallest cutoff angle possible to the cutoff can significantly affect a Saikuni USA c/o Dreamtec Consulting LLC gain the desired results because larger company’s productivity, capability, and 130 Overlook Ave. #TSJ Hackensack, NJ 07601 cutting angles can affect tool life. A good costs. Add to this the possibility of Phone: 201-678-1446 Fax: 201-696-3816 starting point is 7° for a carbide saw grooving and forming, and a company e-mail: [email protected] Sales Reps and 10° for a high speed steel saw. The can then truly revolutionize the way it Needed! standard rake angle is a positive 2-4°. manufactures turned parts. Finally, saw surface treatments must be considered. Surface treatments ABOUT THE AUTHOR: increase tool life and produce better sur- Fritz F. Greulich is president of Watkins GEAR RACK faces finishes. Generally, the same treat- Manufacturing, Inc., which is based in SPECIALISTS ments used on single point tools apply Cincinnati, Ohio. He can be reached at to the saw. Use Table 1 as a guide. (513) 563-0440 or (800) 444-5373. His e-mail With the many technical advantages address is [email protected], and the STOCK, STANDARDS & SPECIAL GEAR RACK 1 rotary sawing offers over single point company’s Web site is [www.saw-lutions.com]. 64 DP TO ⁄2 DP, CIRCULAR & MODULE PITCHES 3 UP TO 31 ⁄4” FACE WIDTH AND 157” CONTINUOUS CUT (LONGER BY RESETTING) QUALITY TO AGMA CLASS II

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46 GEAR SOLUTIONS • OCTOBER 2004 • gearsolutionsonline.com Index of Advertisers

COMPANY NAME PAGE

Abundant Manufacturing, Inc. 44 Allen Adams Shaper Service 44 Arum Advertising 44 Bourn & Koch 14 C-B Gear 23 Carnes Miller Gear 32 Circle Gear & Machine, Inc. 44 Clarke Engineering IFC Clifford Jacobs Forging Co. 22 CNC Machinery, Inc. 39 Cosen Saws USA 46 Drewco 14 Eirsa de cv 44 eldec USA 44 Encoder Products 21,32 EuroTech Corporation 8 Gear Manufacturing, Inc. 33 Gear Solutions Online 43 Global QA 15 GTC Falcon 45 Hanik Corporation 45 High Performance Gear 9 Horsburgh & Scott Co 45 Innovative Rack & Gear Co. 45 IonBond 35 KAPP Technologies 1 KaWood Gear 45 King Precision Tech 45 Kreiter-Geartech 45 mG miniGears 35 Midwest Gear Corporation 45 Mitsubishi Gear Technology Center BC Mohawk Machinery 31 Moore Addison 45 Moore Gear & Manufacturing 34 Nachi Machining 2 New England Gear 5 Perry Technology 19 R. P. Machine Enterprises, Inc. 40,47 Raycar Gear & Machine 39 Repair Parts, Inc. 34 Russell Holbrook & Henderson 7 Saikuni/Dreamtec 46 Setco 22 Spectrum Machine, Inc. 33 St. Louis Gear Co. 38 Standard Steel Specialty Co. 46 The Broach Masters IBC The Gear Works-Seattle 46 Timco 29 Tyrolit 20 UFE, Inc. 27 Wichita Clutch 38 Willman Industries 23

gearsolutionsonline.com • OCTOBER 2004 • GEAR SOLUTIONS 47 Our Conversations with Industry Leaders QQ&&AA Our Conversations with Industry Leaders

with Chris Vian Vice President, The Broach Masters, Inc.

GS: I understand that you had a booth at IMTS. that we’d been running every day, rented about What was it like this year? 1,200 feet of space, and moved out on our own. CV: A lot better than 2002. There was more Mark is president of the company, and he also optimism, with people saying they’re busy and handles engineering and sales. I’m vice presi- getting busier, so that’s always a good thing to dent, and I oversee manufacturing of the cutting hear. I think everybody has a much more posi- tools along with engineering. And then Scott is tive attitude about the economy and the way also vice president, and he deals with quality things are going than they did even a year ago. control, the production department, and specialty I’m excited about this machines for our own use. GS: Do you attend Gear Expo as well? uptick in the economy, CV: We do. Attending IMTS is a good way to GS: Your Web site says “Broach Masters- the growth we’ve experi- expose us to different people than those who go Universal Gear Company.” Is that the result to the AGMA show. We do a lot of work in aero- of an acquisition? enced, and the potential space, but attending both shows allows us to CV: About eight years ago a friend ours by the this company has in terms meet people in other sectors of the industry as name of Ron Muller was interested in selling his well. And while we might meet the guy who company, Universal Gear Co., which made shank of the future. designs the parts at Gear Expo, maybe we’ll and small disk cutters. Ron had been making meet the guy who actually runs the machine at shaper cutters for 25 years, and he was thinking IMTS—and he may also be the one who orders about retiring at the time. But the good thing is “ the tooling. So attending both shows really gives that he came to work for us, and we’re benefiting us a pretty good cross section of the industry. from his expertise to this day. And it was a really great opportunity for us to meld our strengths in GS: What did you focus on at IMTS? broaches, gears, and grinding with his in manu- CV: We go up to 180 diametrical pitch on our facturing shaper cutters for the benefit of every- broaches, and in our shaper cutter line we one. We’ve expanded our capabilities to include ” showed some of our shank and disk cutters. up to 6” PD disk cutters and master gears. We One tool we showed is a multi-pitch cutter that have been blessed to work with some visionary can cut two different splines on a part in one toolmakers, including Ron and our father, Don. sitting on a CNC shaper, as well as some fine They are two of the really great ones. pitch broaches and ring gears for planetary systems. We’ve also added master gears to our GS: Back to the optimism you mentioned pick- repertoire along the way, and we have all the ing up on at IMTS, do you share that sense? inspection equipment we need to check them. CV: Yes, I do. I’m excited about this uptick in So we’ve spent a great deal of money upgrad- the economy, the growth we’ve experienced, ing our equipment, and we wanted to let people and the potential this company has in terms of know about everything we can do now. the future. We’ve been investing in new equipment, so we’re ready to take advantage of new GS: How long has Broach Masters been in opportunities in the coming years. It’s really business? going to be exciting. CV: My brothers and I started the company in 1978. The three of us started working for our dad when we were all 12 to 13 years old, sharp- For more information contact ening broaches and running machines in a shop that he owned. So by the time we were in our Chris Vian at (530) 885-1939 late teens we were spline grinding and OD grind- or send e-mail to chris@ ing and engineering the cutting tools ourselves. broachmasters.com. Visit online And then when dad’s company started growing in another direction, we bought the machines at [www.broachmasters.com].

48 GEAR SOLUTIONS • OCTOBER 2004 • gearsolutionsonline.com

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