Design Features of Worm Gearing Composed Plastic And/Or Powder-Metal Components

GEAR SOLUTIONS MAGAZINE

Your Resource for Machines, Services, and Tooling for the Gear Industry DESIGN FEATURES OF WORM GEARING COMPOSED PLASTIC AND/OR POWDER-METAL COMPONENTS

ISSUE FOCUS Powder Metal Gears | Chamfering & Deburring DESIGN FEATURES OF WORM GEARING COMPOSED OF PLASTIC AND/OR POWDER-METAL COMPONENTS

COMPANY PROFILE ATLANTA GEAR WORKS AUGUST 2019

AUGUST 2019 gearsolutions.com FCG-Ad-General-8.375x10.875.pdf 1 4/11/19 10:58 AM

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New Genesis® GX Series takes gear grinding quality and DESIGN FEATURES OF WORM GEARING COMPOSED OF productivity to an entirely new PLASTIC AND/OR POWDER-METAL COMPONENTS level, with single-tool setup, The technology used in production of plastic gears, as well as 36 integrated automation, twist- powder-metal technology, both impose certain constraints on the design controlled and polish grinding – parameters of a worm and of a mating gear. and Closed Loop networking By STEPHEN P. RADZEVICH with GMS® inspection. www.gleason.com/GX TAKING DEBURRING TO THE NEXT LEVEL Recent developments from Helios Gear Products increase the productivity 42 of the company’s Tecnomacchine CNC gear deburring technology. By GEAR SOLUTIONS STAFF

‘ANY MAKE, ANY MODEL, ANYTIME, ANYWHERE’ COMPANY PROFILE Atlanta Gear Works designs, engineers, builds, rebuilds, and repairs heavy industrial gearboxes for some of America’s leading 46 manufacturers with one main goal — to minimize or prevent downtime. By KENNETH CARTER

MPT EXPO IS ALL ABOUT INNOVATION. Learn about the research driving the next generation of innovation in mechanical, fluid power, electric, and hybrid technologies at the MPT Conference, AGMA’s Fall Technical Meeting, and other education seminars. And then experience it hands-on with new products and demonstrations inside the exhibit hall. BOOTH OCTOBER 15–17, 2019 COBO CENTER | DETROIT, MICHIGAN A PREVIEW AND DETAILS OF THE MPT EXPO » PAGES 21–28 OCTOBER 15-17, 2019 #3400 DETROIT, MI August 2019 3 © Gleason Corporation. All rights reserved. Visit us at Booth 3009

Manufacturers of:

and Universal Gear Company 1605 Industrial Drive Auburn, CA 95603 Phone: (530) 885-1939 Fax: (530) 885-8157

4 gearsolutions.com AUGUST 2019 • VOLUME 16, NUMBER 8 DEPARTMENTS 8 INDUSTRY NEWS Reports, data, and developments to keep you aware of what’s happening with your colleagues in the gear-manufacturing industry around the country and world. GMTA to present ‘Micro-Finishing’ Motion Industries names Jeremy Barton as technology at MPT Expo VP of West Group

In this section, the premier supporter of gear manufacturing in the United States and beyond shares news of the organization’s activities, upcoming American educational and training opportunities, technical meetings and seminars, Gear Manufacturers standards development, and the actions of AGMA councils and committees. 17 Association

30 MATERIALS 32 TOOTH 34 HOT MATTER TIPS SEAT WILLIAM P. NEBIOLO BRIAN DENGEL D. SCOTT MACKENZIE SELECTING MEDIA FOR OPTIMUM WHAT DO YOU DO? I SELL GEARS! BACK TO BASICS WITH TEMPERING VIBE BOWL GEAR FINISHING What reaction do you get at a cocktail (PART II) Choosing the best media depends on party when you try to explain your Fundamental methodology for calculating structure and shape of the tooth flank, profession? tempering times and temperatures for steels and whether media components should can simplify the empirical determination of be abrasive, non-abrasive, or a blend. appropriate temperatures to use to process a new part.

50 PRODUCT 56 SHOWCASE Q&A New products, trends, services, and developments in the gear industry.

RESOURCES 54 MARKETPLACE

55 ADVERTISER INDEX T.J. BOUDREAU Category manager with COVER PHOTO: SHUTTERSTOCK (2), DIRECT INDUSTRY / ILLUSTRATION BY RICK FRENNEA Weiler Abrasives Group

Gear Solutions (ISSN 1933 - 7507) is published monthly by Media Solutions, Inc., 266D Yeager Parkway, Pelham, AL 35124. Phone (205) 380-1573 Fax (205) 380-1580 International subscription rates: $72.00 per year. Periodicals Postage Paid at Pelham AL and at additional mailing offices. Printed in the USA. POSTMASTER: Send address changes to Gear Solutions magazine, P.O. Box 1210, Pelham, AL 35124. Publications mail agreement No. 41395015 return undeliverable Canadian addresses to P.O. Box 503 RPO West Beaver Creek, Richmond Hill, ON L4B4R6. Copyright ©2006 by Media Solutions, Inc. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopy, recording, or any information storage-and-retrieval system without permission in writing from the publisher. The views expressed by those not on the staff on Gear Solutions magazine, or who are not specifically employed by Media Solutions, Inc., are purely their own. All “Industry News” material has either been submitted by the subject company or pulled directly from their corporate website, which is assumed to be cleared for release. Comments and submissions are welcome, and can be submitted to [email protected].

August 2019 5 FROM THE David C. Cooper PUBLISHER EDITOR Chad Morrison ASSOCIATE PUBLISHER The many facets of additive EDITORIAL manufacturing continue to grow Kenneth Carter ou’d have to be manufacturing stuff under a rock not to have heard how additive manu- EDITOR Yfacturing and 3D printing are poised to be a game changer in the gear-manufacturing Jennifer Jacobson world. ASSOCIATE EDITOR Not only is it expected to change the way products are made, but also the way those Joe Crowe products are distributed, according to a recent study from Carnegie Mellon University CONTRIBUTING EDITOR and the University of Lisbon. The advent of 3D printing could throw out the need to keep stockpiles of spare parts in storage, where they wait to be needed. SALES With 3D printing, parts could be quickly manufactured on an as-needed basis, espe- Chad Morrison cially for non-critical parts, according to the research. ASSOCIATE PUBLISHER However, the study is quick to point out that, even though printing the parts may Dave Gomez lower the cost of inventory, the machines needed to process a freshly created part are NATIONAL SALES MANAGER still quite expensive. However, it is a fascinating look at how 3D printing is changing the way industries are Tom McNulty REGIONAL SALES MANAGER formulating their business models. Even though additive manufacturing is making inroads in gear production, specifically with spur gears made from powder metal or plastic, it’s still a process that can be costly CIRCULATION when applied to worm gears. Teresa Cooper In this month’s cover article, frequent contributor Stephen Radzevich shares his insights MANAGER on how the design features of worm gearing made of plastic or PM metals can affect the parameters of the worm and mating gear. Jamie Willett ASSISTANT Our August issue also covers deburring, and an article from Helios looks at the com - pany’s upgraded CNC gear deburring machine and how it may revolutionize how gears are deburred. DESIGN A special bonus includes exciting details about AGMA’s Motion + Power Technology Rick Frennea Expo coming up fast in October in Detroit. In eight pages, AGMA takes you through all CREATIVE DIRECTOR the amazing topics that will be shared in dozens of daily sessions, including the annual Fall Technical Meeting where technical papers are presented. Many of those papers you’ll Michele Hall GRAPHIC DESIGNER find reprinted in future issues of Gear Solutions. There’s all that and much more in the August issue. I hope you find it as informative as I did. CONTRIBUTING As always, thanks for reading! WRITERS Brian Dengel D. Scott MacKenzie William P. Nebiolo Phillip Olson Stephen P. Radzevich

KENNETH CARTER, editor [email protected] Vertical Logo Horizontal Logo (800) 366-2185 x204

PUBLISHED BY MEDIA SOLUTIONS, INC. Coop wants to use this one for the website CALL FOR ARTICLES Have a technical paper or other work with an educational angle? Let Gear Solutions publish it. Contact the editor, P. O. Box 1987 • Pelham, AL 35124 Kenneth Carter, at [email protected] for how you can share (800) 366-2185 • (205) 380-1580 fax your expertise with our readers. David C. Cooper Chad Morrison PRESIDENT VICE PRESIDENT Teresa Cooper 6 gearsolutions.com OPERATIONS FELLOWS 50-8/50-12 GEAR SHAPERS HYDROSTROKE SHAPERS • REMANUFACTURED IN 2017 Yeah, we’ve got that!

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343 JOHN DOWNEY DRIVE • NEW BRITAIN, CT 06051-2907 • PHONE 860-223-7778 • FAX 860-223-7776 • [email protected] Xxxxxxxx 201X 7 INDUSTRY NEWS NEW TRENDS, SERVICES & DEVELOPMENTS

ishing process reduces friction, increases pitting resistance and the life of gears. This process uses a high-quality diamond plated tool designed to remove only a small amount of part material. The resulting part greatly increases surface quality on the gear teeth. The Micro-Finishing technology can be applied as a stand-alone process on a Scudding machine, a sequential process where Hard Scudding and Micro-Finishing are completed using a tandem tool set-up, or it can be applied on a double Profilator machine. The processes of Hard Scudding and Micro-Finishing can be completed simultaneously. GMTA will be at booth 4439.

MORE INFO www.gmtaamerica.com Motion Industries names Jeremy Barton

GMTA will feature its Profilator® line of gear pointing, rounding, cutting, Scudding®, Hard Scudding®, as VP of West Group deburring, and polygon machine tools for North America at Motion+ Power Technology Expo. (Courtesy: GMTA) Motion Industries, Inc., a leading distribu- tor of maintenance, repair, and operation GMTA to present hardened gears on the same machine, using replacement parts and a wholly owned the same programs. Furthermore, it is a supe- subsidiary of Genuine Parts Company, has ‘Micro-Finishing’ tech rior technology to skiving, the previous tech- named Jeremy Barton to vice president of at MPT Expo nology used in the gear industry. the company’s West Group, effective August While Profilator GmbH & Co. KG intro- 1, 2019. With more than 300 exhibiting companies, duced the concept of Hard Scudding in Barton will the Motion + Power Technology Expo is the 2015, it expanded scudding technology with lead Motion’s West ideal show for gear, electric, and f luid power “Micro-Finishing.” Micro-Finishing takes Group operations industries. GMTA is one of the exhibitors at place after the Hard Scudding process has with more than 20 the event in Detroit, Michigan, October 15-17. been completed. The process takes a high- years of experience GMTA will feature its Profilator® line of quality Hard Scudding part and improves garnered from serv- gear pointing, rounding, cutting, Scudding®, its surface quality. Additionally, this is ing in a variety of Hard Scudding®, deburring, and polygon a completely dry machining process and key roles within machine tools for North America. The highly requires no cutting fluids or MQL technol- Motion Industries. Jeremy Barton modular machines are used for polygon and ogy. The total cycle time for finishing a ring He has worked as an slot facing, shifter stop machining, cham- gear via Hard Scudding and Micro-Finishing industry sales manager (mining), and branch fering, and deburring of highly complex is approximately 64 seconds, but the cycle manager (Salt Lake City), as well as providing automotive and other powertrain gears. The time could be decreased by 10 percent, keep- technical, sales, and operations guidance for “Scudding®” and the “Hard Scudding®” pro- ing it under one minute for all automotive the company’s growing industrial services cess sets the Profilator apart in the market gear rings. platform in the West. In 2016, he was promot- because of its manufacturing efficiency. Hard Micro-Finishing technology is aimed at ed to his most recent position as Mountain Scudding allows the machining of green and making a quieter gear, and the superfin- Division sales manager.

SEND US YOUR NEWS Companies wishing to submit materials for inclusion in Industry News should contact the editor, Kenneth Carter, at [email protected]. Releases accompanied by color images will be given first consideration.

8 gearsolutions.com Barton obtained Six Sigma/Lean/5S certi- Supply Chain, presented by CalAmp. fication in 2011, and holds various business Economic Outlook and Trends within management, technical & leadership certi- the Industrial Fluid Power Market, presented fications. by Oxford Economics. Kevin Storer, Motion Industries execu- Blockchain: The Future of Manu- tive vice president of U.S. Operations, said, facturing, presented by SIMBA Chain. “Jeremy brings valuable experience and Effective Contract Negotiations: The expertise to this position, and we are confi- Path to Commercial Success with Large OE dent that he will succeed in leading the West Customers, presented by Rouse Contract Group. I know he’ll do an outstanding job Consultants, LLC. driving our key field initiatives.” The Evolution of the Automotive Motion Industries President Randy Powertrain, presented by IHS Markit. Breaux said, “We are very happy with the Workforce Development Using a Farm selection of Jeremy as the West Group Team Approach, presented by Scot Forge. Vice President. Jeremy has earned this Cybersecurity Hygiene in Motion, pre- position through his leadership and per- sented by (ISC)2 Central Florida Chapter. formance over the past years. I am excited Hire Like Nobody’s Business, presented about the future of the West Group under by Diversified Industrial Staffing. Jeremy’s direction.” EMERGING TECHNOLOGY TRACK MORE INFO www.motionindustries.com Simplifying Industrial IoT for Discrete Manufacturers, by MachineMetrics. The Future of eMobility in the MPT Expo sets Commercial Vehicle Space, presented by Meritor . conferences on business, Processes and New Machines for 3D Printing Metal, presented by The Barnes emerging technology Group Advisors. The Motion + Power Technology Expo, for- The End of Fear: How Collaborative merly Gear Expo, has expanded its educa- Industrial Robots Will Change Durable tional offerings as part of this year’s event Goods Manufacturing, presented by Veo October 15-17, 2019, at the Cobo Center in Robotics. Detroit. For the first time, the event will Standards for IIoT Interoperability, pre- offer an all-new MPT conference program sented by MTConnect. with 16 sessions offered in two tracks: Losing Teeth? The Future of Gear Trains Emerging Technology and Business. in the Age of Electrification, presented by Attendees will learn from industry Schaeffler. experts on the hottest topics including Materials Challenges and Solutions cybersecurity, supply chain, 3D printing, in Additive Manufacturing, presented by robotics, and much more. The event is pro- QuesTek Innovations, LLC. duced by the American Gear Manufacturers Collaborative Operation in Industry Association (AGMA) and the National Fluid Today, presented by FANUC America Power Association (NFPA), and will be co- Corporation. located with the ASM Heat Treating Society Conference and Exposition. MORE INFO www.agma.org “We are excited to be offering an outstand- www.motionpowerexpo.com ing conference program to run alongside our expansive exhibit hall. Attendees will have access to a great line-up of thought leaders ANCA Tool of the Year who will share their knowledge of several important topics impacting the power trans- winners to be announced mission industry,” said Jenny Blackford, vice president, marketing, AGMA. “Attendees will live at EMO 2019 be able to learn about the research driving ANCA Tool of the Year Award 2019 celebrates the next generation of innovation at the MPT the knowledge and imagination of cutting Conference, AGMA’s Fall Technical Meeting, tool craftsmen, creating tools with the per- and other education courses.” fect geometry, profile, and finish that shape The following conference sessions will be and build the world. October 16-17: ANCA’s industry-first competition is back, with the 2019 winner to be announced live BUSINESS TRACK at EMO, Germany, September 16-21. Last year, Improve In-Transit Visibility to Reduce the industry welcomed the opportunity to

August 2019 9 INDUSTRY NEWS show off its skills with almost 30 entries received from across the world being seen by more than 122,000 fans generating 3,000 comments and reactions on social media. Pat Boland, ANCA co-founder, said, “I have great respect for our customers’ knowledge in designing and grinding quality cutting tools. Their skills drive our industry forward and most of ANCA’s new technology is born from a customer’s need to achieve something new.” “We should celebrate the collective acu- men of our industry and showcase the fantastic work that is conducted every day to build our world. I encourage all cutting tool makers to enter our competition and show off your talents,” he said. The cutting tool industry has cultivated and refined its craft over the years to design beautiful tools, applying science to achieve a Contour 360 was the 2018 winner of the ANCA Tool of the Year competition. Other finalists were Daily Grind sub-micron surface finish and superior cut- Industrial Tool, Acu Twist, Miltera, SAN Engineering, and Kazimieruk. (Courtesy: ANCA) ting performance. With 2,200 exhibitors and 130,000 visitors, EMO remains a key event in “Technology is moving forward faster than to ANCA and their customers, revolutionary the cutting tool makers calendar and is the ever, demanding more and more of the tool new ideas have come to practice making our perfect opportunity to showcase the legends grinders of today. Designing and grinding technology move forward.” who are creating superior cutting tools. these great products demands for a combina- ANCA will also launch the ToolRoom Ralph van Hoorn, managing director at tion of great ideas combined with technical RN34 software package at Hall 6, Booth J35. Van Hoorn Carbide and first-time judge, said, knowhow and top-class machinery. Thanks ToolRoom plays a crucial role in enabling tool

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10 gearsolutions.com grinders to design and execute high-quality the most talented and capable toolmakers I At EMO, the top five tools will be judged cutting tools. Specializing in complex cut- have ever met. And they represent an entire on the following criteria: ting tool geometries for the aerospace, die organization of others just like them.” Best surface finish in Ra (roughness mould, and power generation industry, the To find the Tool of the Year, ANCA will average) value on the flute or gash surface. latest package can design and manufacture hold a competition for customers to submit The tool that is closest to the nominal complex tool geometries as well as balance their favorite tool with the winners judged tolerance as stated on the drawing in terms them for optimal cutting conditions. New is and announced live at EMO. The prize is of diameter and profile (i.e. if the tolerance the endmill cycles for ballnose and corner a trip for two to ANCA headquarters in on diameter is +/- 0.010mm and the tool radius, tool balancing, and next-generation Melbourne, Australia, to see firsthand how is measured to 0.005 then this will rank fluting cycles. the technology is created at ANCA and favorably). “All finalists from last year were of a meet the team who are dedicated to find- Tool that has been ground to the tight- very high standard and demonstrated a ing even better solutions for our customers. est tolerance as per the drawing (i.e. the tool deep understanding for tool geometry as The winner also receives a copy of the latest with the lowest tolerance will rank favorably). well as taking full use of ANCA’s software. ToolRoom RN34 software release. Level of complexity (i.e. in terms of the We congratulate the winner, Contour360, The competition will be based on the number of steps, profiles will rank favorably). and other finalists Daily Grind Industrial passion and the craft of tool making and Tool, Acu Twist, Miltera, SAN Engineering, celebrate the highly skilled tool grinding MORE INFO machines.anca.com/ and Kazimieruk for their efforts,” ANCA’s community. Tool-Of-The-Year Boland said. Judging panel: Charles R. Day, vice president and gen- Pat Boland, co-founder and managing eral manager at Contour360 and winner of director at ANCA. Bourn & Koch parent 2018’s competition said, “In the two years Ralph Van Hoorn, managing director at I’ve been with the Contour360° organiza- Van Hoorn Carbide. company acquires CID tion, I have told everybody who would lis- Thomson Mathew, product manager at ten (and even some who wouldn’t) how over- ANCA. Performance Tooling the-top this company’s toolmaking ability Alicona – measurement of surface fin- Bourn & Koch, an American manufacturer is! Steve Hutchins and Mario Ercolani are ish. of new precision machine tools, announced responsible for the submission and two of Zoller – measure profile and diameter . that its parent company, Alleghany

GEARING AHEAD TO MEET INDUSTRY'S DEMAND FOR PRECISION – SERVING – NEW Aircraft • Aerospace • Actuation Release Instrumentation • Optic 2019 Robotics • Radar • Medical Marine • Defense • Experimental Prototype • Production KISSsoft Highlights Hi-Performance Automotive

▪ Intuitive concept design on system level Precision Gear Products (up to AGMA Q14): with KISSdesign Spur Gears, Helical Gears, Worm Gears, Anti-Backlash Gears, Cluster Gears, Clutch Gears, Visit us at Booth 3400 ▪ Rolling bearing calculation with connection Face Gears, Planetary Gears, Gear Assemblies, Gear Boxes, Bevel Gears, Miter Gears, to SKF cloud Metric Gears, Internal Gears, Idler Gears, Gear Rack & Pinion, Worms, Wormshafts, ▪ Contact pattern of asymmetrical gears Splines, Spline Shafts, Serrated Shafts. ▪ Crossed helical gear with rack KISSsoft AG/Gleason Sales ▪ Feasibility assessment for „Power Skiving“ Brian P. Stringer CNC Thread Grinding Phone (585) 494-2470 [email protected] Free trial version at www.KISSsoft.com STD Precision Gear & Instrument, Inc. 318 Manley St. • W. Bridgewater, MA 02379 (888) STD-GEAR or (508) 580-0035 Fax (888) FAX-4STD or (508) 580-0071 E-mail [email protected] • Web site: www.stdgear.com

August 2019 11

GearSol_KISSsoft_Release2019_92_25x123_83mm.indd 1 09.05.2019 09:06:08 INDUSTRY NEWS

Capital Corporation, has acquired Coastal will include Bourn & Koch, Inc. (“Bourn & share resources and leverage their combined Industrial Distributors LLC, (doing busi- Koch”), Diamond Technology Innovations, capabilities to provide an enhanced prod- ness as CID Performance Tooling); and has Inc. (“DTI”), and CID. uct and service offering to their customers. formed a new holding company for its sub- David Van Geyzel, president and CEO of Alleghany Capital is pleased to welcome CID sidiaries in the machine tool and consum- Alleghany Capital, said, “This transaction to the Precision Cutting Technologies group able cutting tool sectors. furthers Alleghany Capital’s growth strat- of companies and looks forward to support- Headquartered in Saco, Maine, CID egy in the machine tool and consumable ing Bourn & Koch, DTI, and CID as they con- Performance Tooling (“CID”) is a lead - tooling industries. While the formation tinue to serve their markets.” ing manufacturer of high-performance of Precision Cutting Technologies will not Terry Derrico, president of Precision solid carbide end mills. The new holding change the management of Bourn & Koch, Cutting Technologies and Bourn & Koch, company formed by Alleghany Capital, DTI, and CID, it places these companies said, “We are excited to partner with Jay called “Precision Cutting Technologies” under a single platform so that they can Lowery, founder and president of CID, as well as his experienced team, and believe that the employees, customers, and suppliers of all the companies within the Precision Cutting Technologies platform will benefit from this acquisition. CID enhances Precision Cutting Technologies’ portfolio of consumable cutting tools, while expanding our business in the aerospace, defense, and medical end-markets. “With Jay continuing to lead the company post-transaction, CID’s day-to-day operations will not be impacted. However, we believe CID will be well positioned to accelerate growth and augment its geo - graphic reach by leveraging the experience, capabilities, and support of Bourn & Koch, DTI, and Alleghany Capital.” “Over the past 30 years, CID has become a leader in producing the highest quality custom tooling solutions for customers serving the most demanding end-mar - Visit us at Booth 4328 kets,” said CID president Jay Lowery. “As we build on our proven track record of quality, innovation, and service, we are pleased to have found a long-term home for the company and are excited about the opportunities that will result from this transaction.”

MORE INFO www.precision-cutting.com www.bourn-koch.com

Growing Atlanta Gear Works launches new website, brochure Atlanta Gear Works, a full-service gearbox engineering, manufacturing, and repair company, has launched a new website and brochure to accommodate its growing services and customer base. Since its founding in 1988, the company has grown by serving leading manufacturers with innovative power-transmission solutions, high-quality products, and responsive service for its process-critical

12 gearsolutions.com Organizers close in on high demand for exhibition space at AMB 2020,” said Gunnar Mey, department direc- lift-off for AMB 2020 tor industry at Messe Stuttgart. It is certain that the 20th AMB, which will be held at the in Stuttgart, Germany Stuttgart Trade The registration period for AMB 2020 ended Fair Centre, September 15–19, will again on June 30. The project team is now starting be booked completely and will occupy the to examine the registration forms received entire area of the trade fair grounds. and is preparing the first placement propos- Several companies that attended AMB als for the exhibition stands. in 1982 talk about their connection with “AMB is a permanent fixture in the indus- the exhibition, and what makes it so try’s diary. This is also demonstrated by the attractive.

Atlanta Gear Works has a new brochure that emphasizes service as a large part of its offerings. (Courtesy: Atlanta Gear Works) FORGING rotating equipment. Recent growth has caused an expansion of services and plant, with a 10,000-square-foot expansion planned. “We’ve grown because we’re not just a gearbox manufacturing and repair company. We’re also a service company, and our new website and brochure do a better job of AHEAD explaining that to our customers,” said Craig Massa, Atlanta Gear Works VP-sales. Atlanta Gear Works offers a range of OF THE PACK services including gearbox repair, custom gearbox engineering, and manufacturing, custom gearing, in-stock PIV parts and units, and field machining and services, all backed by 24/7 service and support. “Our commitment to customers is to do whatever it takes to prevent and minimize Visit us at Booth 2922 their downtime,” said Atlanta Gear Works President Jack Conway. “We’ll repair any make, any model, anywhere, anytime.” As part of its commitment, AGW has also greatly expanded its field services. Fast. “We can save customers days of downtime by doing troubleshooting and repairs on No Fine Print. their site,” Conway said. No Premium. Atlanta Gear Works field services include gearbox inspection and repair and a wide At McInnes Rolled Rings, we provide quality range of field machining, including line products, shipped fast. And we partner that with boring, hydraulic drilling and boring, and exceptional customer service to forge the perfect journal turning and repair. Available around partnership with our customers. the clock, its field services crews have been known to work overnight to get a customer up and running. 1.877.695.0301  www.McInnesRolledRings.com MORE INFO www.atlantagear.com August 2019 13 INDUSTRY NEWS

truly a joy to help support and advance the capabilities of our customers with a product solution in line with the current trend involving data-driven manufacturing.” Mendicino has designed, sold, serviced, and supported various manufacturing software technologies for the entire span of his career, including CAD, CAM, DNC, OEE, IIOT, Machine Data Collection, ERP, and now QMS at High QA. Most recently, he was the certified reseller of ProShop ERP software in New England, and before that he held several positions at MACDAC Engineering in Somers, Connecticut — ultimately that of product manager for the company’s revolutionary machine data collection package of hardware and software for Industry 4.0 initiatives. Likewise, Moroz has a tremendous depth of knowledge and experience in the engineering and applications aspects of complex software programs and systems since 1982. The 20th AMB at the Stuttgart Trade Fair Centre September 15-19, 2020, again will be booked up completely and Before joining High will occupy the entire area of the trade fair grounds. (Courtesy: Messe Stuttgart) QA, his most recent positions were at Lothar Horn, managing director of Paul High QA appoints Alloy Software in Horn GmbH, sees a special connection with Bloomfield, New AMB. new positions Jersey as a technical “We have a close association with AMB support engineer and have grown continuously together. In to support growth and software quality Chris Mendicino 1982, we exhibited at the event as a small High QA, Inc., the developer of Inspection assurance engineer. Swabian company,” he said. “Nowadays, we Manager™ Quality Management Software, “We at High QA take part in AMB as the world market leader has appointed Christopher (Chris) are delighted to for precision tools. For us, AMB is like our Mendicino to the position of vice president have these two own living room where we welcome our cus- of Professional Services and Jim Moroz to gentlemen on our tomers. It also clearly sets the standard as the position of senior software support team to provide to what we want to present in terms of new applications engineer. In their respective our customers with products and innovations.” roles, Mendicino and Moroz are responsible the highest level of Holger Hehl, area sales manager at for onboarding, installation, conducting technical support Chiron-Werke GmbH & Co. KG, said AMB is basic and advanced training, assisting with services in a consis- Jim Moroz definitely the centerpiece of machine tool software implementation to ensure all of its tently professional construction and the ideal meeting point for features and benefits are attained, and pro- manner,” said Sam Golan, High QA’s founder the industry in southern Germany. viding a full range of follow-up and support and CEO. “Every world market leader presents their services. High QA’s customers work in a range High QA is a team of design, manufactur- innovations here and we have a platform to of manufacturing industry sectors. The coming, software development, and supply chain show metal cutting in detail to customers pany created the new positions to accommo- experts with more than 100 years of hands- and interested parties,” Hehl said. date increasing global product sales and to on experience in mechanical engineering, Werner Gerstner, sales manager at Carl maintain its superior level of responsiveness manufacturing, inspection, PLM, lean manu- Zeiss AG, attended the first AMB in 1982 that consistently receives high marks from facturing, and developing quality software and is still impressed by the exhibition customers. The recent growth is projected to products. The organization is committed concept. continue at High QA as more manufacturers to the automation of quality assurance “AMB has always set standards and sup- are automating their quality and inspection processes. Its flagship product, Inspection ported a large number of changes in tech- processes and establishing centralized data Manager, is highly intuitive, user-friendly nology,” he said. “Every important topic is collection systems. and cut costs and time, sets consistent stan- examined here and exhibitors show their “In essence, our function is all about help- dards and best practices, and ultimately portfolio solutions relating, for example, to ing people be successful implementing our helps quality control departments improve electric mobility, Industry 4.0 or the Internet highly automated inspection software that the profitability of manufactured parts and of Things.” can literally transform their work lives, lead- enrich customer satisfaction. ing them to new levels of success and growth MORE INFO www.amb-messe.de in their companies,” Mendicino said. “It’s MORE INFO www.highqa.com 14 gearsolutions.com Telescopic Handlers rose to more than 700 smoother movement of the boom. The design Italian manufacturer machines per year – with annual growth principle ensures uniform load balancing Magni reaches new rates of 30-40 percent. across the individual stages, resulting in a Successful operation of these handling high-power density. All Liebherr sun gears heights with Liebherr machines requires precise control over the and planet gears are optimized to minimize load even at greater lifting heights. Magni circumferential backlash and have mini- Magni’s company history is short, but none- rotary telehandlers operate at heights of mum play. The inner gears are made of tem- theless amazing: In just five years, the Italian up to 46 meters — which means the manu- pered steel, which is also used for the planet manufacturer has become the premium pro- facturer holds the current world record for carriers. The first jointly produced machines vider of rotary telehandlers. These machines rotating models. were successfully tested in 2017. Now, Magni make load handling easy at heights of up to “Moving with absolute accuracy and preci- equips nearly all models with the slewing 46 meters, with impressive flexibility, pre- sion is the top priority,” said Enrico Menozzi, drives from Liebherr Components. The 300th cision, and safety — not least thanks to the head of sales Europe Drive Technology at drive was recently delivered to Italy. three-stage slewing drives from Liebherr Liebherr Components in Biberach (Germany). “These gearboxes are the best compo - Components. The Italian-German partner- The two companies first came into nents that we could find on the market. ship is, therefore, a win-win situation for contact at the 2016 INTERMAT exhibition Liebherr has the best technology, and we both companies. in Paris, where they both recognized the are happy to be able to use it. Together, we “Our machines are sometimes compet- improvement potential in the rotary unit. are indeed a good combination that brings ing with cranes weighing 40 to 50 tons — in As a result, a Liebherr drive unit has been us great benefits,” said Magni. Menozzi said, contrast, however, they are much smaller, used in Magni telehandlers since 2017. It “We have a very solid, open working relation- more versatile, nimbler and less expensive. consists of a type DAT 200 backlash-free ship that benefits everyone, especially our Yet they perform all the required tasks gearbox, a high-pressure, high-speed customers. Magni was very open to sugges- and even combine the three functions of hydraulic motor, and special brakes. The tions from the beginning, so we found a a crane, forklift, and work platform,” said entire slewing drive increases the machines’ new solution together.” CEO and founder Riccardo Magni, briefly precision and stability, and allows safe work- Menozzi benefited from the in-house listing the advantages that explain the ing at greater heights. expertise of the Liebherr Components success of his rotary telehandlers. Within Compared to single-stage solutions, the Division in the development and produc- a short time, production figures at Magni three-stage drives from Liebherr enable tion of slewing drives for their own mobile

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August 2019 15 applications. “We have longstanding experi- tion and maximum quality. Customers could replacement kit with Liebherr.” ence in this area. We also supply drives for recently see the results of this great partner- turntable ladders and fire engines. The larg- ship at the Bauma trade fair, where Magni’s MORE INFO www.liebherr.com est of these can reach a height of 64 meters rotary telehandlers were a big attraction. “We with people on them — high-precision posi- entered the market at the right time, which tioning and smooth control being thereby certainly helped our success. Flexible solu- New short film goes a vital precondition. This know-how is now tions are in high demand,” Magni said. “We applied at Magni.” are now the No. 2 provider worldwide. on a journey The partnership between Magni and “Many of our customers have now tested Liebherr creates valuable synergies. The two the new models with the Liebherr drives – to redefine the kilogram family- run companies are united in their and many want us to swap out their existing In an act of cooperation, the General pursuit of continuous technical optimiza- units. So, at the moment we are planning a Conference of Weights and Measures member states voted to adopt a new kilogram definition for the first time since institut- ing the international prototype kilogram, or IPK, in 1889. This was the culmination of the years-long effort to create greater con- stancy in mass measurement examined in The “Everything Different, Nothing Changes: Visit us at Booth 4316 Redefinition of the SI Unit Kilogram,” a new short video by Mettler Toledo. Power At a basic level, all standards including 2 mass are now tied to fundamental natural of One constants. In the case of mass, the refer- enced value is the Planck constant, also known as the fundamental constant of Your Objective: quantum physics. One face in perfect alignment with another. For infinity. In the 20-minute piece, Christian Müller- Schöll, Mettler Toledo, Dr. Richard Davis, BIPM, and other metrology experts including Dr. Philippe Richard, METAS, explore the science behind the definition, as well as the nearly poetic way the definition was able to be proven. This combination of smart thinking and technological excellence has produced measurement accuracy that is accessible for all people in all places at all times. No problems. No distress. No delays. Rare footage takes you inside areas nor- That’s the same objective you have for choosing your gear producer. mally reserved for only a few metrology Circle Gear’s objective is to engage with every customer’s objectives. experts to witness everything from the high- One to 1000 gears ly technical Kibble balance used to calibrate reference artifacts, to equipment used to cre- Customer designed or reverse engineered ate the enriched silicon sphere that was also Gearbox repair, rebuild or redesign part of the proof. These strong visuals help OEM or end-users to make real the ongoing discussion around the kilogram — a discussion that can seem ISO 9001:2015 Certified largely theoretical, especially to those accus- tomed to dealing with physical weights. The new kilogram definition eliminates 1501 S. 55th Court, Cicero, IL 60804 the need to rely on a physical object located (800) 637-9335 (708) 652-1000 / Fax: (708) 652-1100 in one place, providing a limitless and previ- [email protected] ously unimaginable access to mass-measure- www.circlegear.com ment accuracy. “We are pleased to have been part of the effort to make this new definition

Spiral and Straight Bevel Gears (Cut, Ground or Lapped) • Spur Gears • Helical Gears • a reality,” said Müller-Schöll. Long Shafts • Herringbone Gears • Involute and Straight Sided Splines • Internal Gears • You can watch “Everything Different, Worm and Worm Gears • Racks • Sprockets • ISO Certified Nothing Changes” online at https://youtube/

Partnering with QualityReducer to provide k2XKl9Y7J3s. Gearbox repair, rebuilding and reverse-engineering. MORE INFO www.mt.com/lab 16 gearsolutions.com JennyPhillip BlackfordOlson ViceAGMA President Staff Engineer of American Communications Gear Manufacturers AGMA Association

26 presentations to boast latest gear innovations at 2019 FTM in Detroit

mid the exciting expansion and new offerings of AGMA’s includes a presentation on prototype testing asymmetric gears and 2019 Motion + Power Technology Expo is an endur - a comparison of current surface roughness measurement methods. ing AGMA fixture: The Fall Technical Meeting (FTM). The fifth and final session of the meeting is “Gear Wear and However, despite tracing its roots back to 1917, the FTM Failure.” Attendees will witness thorough discussions on load capaci- isA far from stagnant. This three-day, single-track conference offers 26 ty, scuffing risk, and optimum case depth. Highlights include a newly presentations showcasing the latest, most innovative, peer-reviewed developed method for determining the tooth flank fracture load research in the gear industry. At this annual event, world-renowned capacity of bevel and hypoid gears and a presentation showing how industry experts, academics, and engineers gather to present and to calculate the power capacity of asymmetric gears. attend this meeting to learn about emerging technology and pro- In addition to learning about the latest gear research, the FTM is cesses in their industry. FTM is October 14-16 at the Cobo Center in also a great place for networking. Formal, technical questions can Detroit, Michigan, also the location of the inaugural Motion + Power be posed to the presenters during session Q&As, while more relaxed Technology Expo. networking can take place at breaks between presenters or scheduled The meeting opens with the “Application, Design, and Rating” networking breakfasts, lunches, and dinners. In addition, on Monday, session on Monday afternoon. The six presentations of this topic dive October 14, meeting attendees have the fantastic opportunity to go deep into modeling and showcase some interesting real-world appli- to the FTM Fun and Games Reception at Punch Bowl Social where cations. Highlights include a presentation that proposes an analytical they can bowl, play games, sing karaoke, and enjoy the local fare of model to determine the misalignment and crowned teeth influence Detroit. As always, we encourage attendees to check out the final on spline load capacity and a presentation on the design method of day of the Motion Power + Technology Tradeshow where they can replacing a metal gear with a plastic gear. see some of the research being used in real-time at exhibit booths. The second day of the meeting has both a morning and afternoon We look forward to seeing you this October! session. In the morning session, “Efficiency, Lubrication, Noise and For more information visit motionpowerexpo.com/fall-technical- Vibration,” attendees can look forward to three presentations solidly meeting or contact AGMA at 703-684-0211 or at [email protected] . in the NVH category — one presentation that evaluates eight different algorithms to com- pute gear sliding losses and one presentation highlighting a new water-based lubricant. Tuesday’s afternoon session, “Materials and Heat Treatment,” begins with an evaluation of steel cleanliness by extreme value statistics, then follows with a presentation on tooth-root testing of steels with high cleanliness. After a presentation on 4D high pressure gas quenching, a new, alternative gear steel is presented, then the session clos- es by presenting information on gears with alternative microstructures. The final day of the FTM, Wednesday, October 16, also has two sessions. In the morning session, “Manufacturing, Inspection and Quality Control,” a study on the influence of manufacturing variations on spline root and contact stress is presented between two presentations on new manufacturing processes for chamfering gears and micro skiving gears, respectively. The session also A session from the 2018 Fall Technical Meeting. (Courtesy: AGMA)

August 2019 17 AGMA now offers Supply online. Topics covered in this six-course program include: Chain Management Integrated Supply Chain Management. Inventory Management. courses! Manufacturing and Service Operations. Order Fulfillment and Customer Service. Through funded research from the AGMA Foundation, AGMA and Transportation and Warehousing. Ranken Technical College have teamed up to provide the gear indus- The program curriculum also will prepare students for the try with Supply Chain Management courses that are conveniently Council of Supply Chain Management (CSCM) SCPro Certification. To

American Gear Manufacturers 18 gearsolutions.comAssociation find out more, visit: www.agma.org/education/online/supply-chain- reviewed. Learn the steps and issues involved in design refinement managment-certification-program. and some manufacturing considerations. An explanation of basic gear measurement techniques, how measurement equipment and test machines implement these techniques, and how to interpret the Upcoming AGMA courses results from these basic measurements also will be covered. Basic Training for Gear Manufacturing Gear Failure Analysis SEPTEMBER 9-13, 2019 | CHICAGO, ILLINOIS NOVEMBER 6-8, 2019 | ST. LOUIS, MISSOURI

Learn the fundamentals of gear manufacturing in this hands-on Explore gear failure analysis in this hands-on seminar where stu- course. Gain an understanding of gearing and nomenclature, prin- dents not only see slides of failed gears but can hold and examine ciples of inspection, gear-manufacturing methods, and hobbing and those same field samples close up, and use of a microscope to exam- shaping. Using manual machines, develop a deeper breadth of per- ine field samples. spective and understanding of the process and physics of making a Class hours: 8 a.m.-5 p.m. This course is taught at Ranken Technical College. A shuttle bus is available each day to transport students to and from the hotel. Online Education Don’t have the ability to come to one of AGMA’s fantastic face-to-face courses? We understand that you are busy, and that is why we offer online education to meet your schedule. Now you can grow your gear knowledge, get the same quality AGMA education, and save money on travel by learning directly at your own computer. AGMA’s online education courses include: Gear Failure Analysis. Gearbox CSI: Gears Only. Detailed Gear Design–Beyond Simple Service Factors. Fundamentals of Gearing. Hobbing. Parallel Gear Inspection.

gear as well as the ability to apply this knowledge in working with CNC equipment commonly in use. This course is taught at Daley College. A shuttle bus is available each day to transport students to and from the hotel. Fundamentals of Gear Design and Analysis SEPTEMBER 17-19, 2019 | CHICAGO, ILLINOIS

Gain a solid and fundamental understanding of gear geometry, types and arrangements, and design principles. Starting with the basic definitions of gears, conjugate motion, and the Laws of Gearing, learn the tools needed to understand the inter-relation and coor- dinated motion operating within gear pairs and multi-gear trains. Basic gear system design process and gear measurement and inspection techniques also will be explained. In addition, the fundamentals of understanding the step-wise process of working through the iterative design process required to generate a gear pair will be

AGMA has over 1,000 Twitter followers! Join the conversation @agma

1001 N. Fairfax Street | Suite 500 | Alexandria, VA 22314 | (703) 684-0211 | www.agma.org August 2019 19 CALENDAR OF EVENTS Whether you’re looking for technical education, networking opportunities, or a way for your voice to be heard in the standards process, AGMA has something to offer you. If you would like more information on any of the following events, visit www.agma.org or send an email to [email protected].

August 6 — Helical Gear Rating Committee Meeting — WebEx August 14 — Helical Enclosed Drives High Speed Units Committee Meeting — WebEx August 14-15 — TDEC — Chicago, Illinois August 20-21 — Aerospace Gearing Committee Meeting — AGMA Headquarters, Alexandria, Virginia

AUGUST August 22 — Lubrication Committee Meeting — WebEx August 22 — Helical Enclosed Drives Marine Units Committee Meeting — WebEx

September 3 — Metallurgy and Materials Committee Meeting — WebEx September 5 — Gear Accuracy Committee Meeting — WebEx September 11 — Bevel Gearing Committee Meeting — WebEx September 24 — Plastics Committee Meeting — WebEx SEPTEMBER

October 14-16 — Fall Technical Meeting — Detroit, Michigan October 15-17 — Motion + Power Technology Expo — Detroit, Michigan October 22 — Helical Gear Rating Committee Meeting — WebEx

OCTOBER October 24 — Metallurgy and Materials Committee Meeting — WebEx

AGMA LEADERSHIP

John Cross: Chairman Zen Cichon: Innovative Rack & Gear Company ASI Drives Michael Engesser: Reishauer Corporation Greg Schulte: Treasurer Bonfiglioli USA Bent Hervard: CFT Michael McKernin: Chairman, BMEC Ruth Johnston: Croix Gear & Machining Circle Gear and Machine Company, Inc. Chalmers & Kubeck Inc. Todd Praneis: Chairman, TDEC David R. Long: Cotta Transmission Company, LLC Jack Masseth: Meritor, Inc. Jim Bregi: Chairman Emeritus Scott Miller: Caterpillar, Inc. EXECUTIVE COMMITTEE Doppler Gear Company Gary Neidig: ITAMCO Matt Croson: President Shawn O’Brien: McInnes Rolled Rings

Amir Aboutaleb: VP, Technical Division BOARD OF DIRECTORS Cory Ooyen: Global Gear & Machining, LLC Jenny Blackford: VP, Marketing STAFF Jill Johnson: Director, Member Services Carl D. Rapp: The Timken Company Casandra D. Blassingame, M.Ed.: VP, Education Services Sara Zimmerman: Sumitomo Drive Technologies

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

20 gearsolutions.com August 6 — Helical Gear Rating Committee Meeting — WebEx August 14 — Helical Enclosed Drives High Speed Units Committee Meeting — WebEx August 14-15 — TDEC — Chicago, Illinois August 20-21 — Aerospace Gearing Committee Meeting — AGMA Headquarters, Alexandria, Virginia August 22 — Lubrication Committee Meeting — WebEx August 22 — Helical Enclosed Drives Marine Units Committee Meeting — WebEx

October 14-16 — Fall Technical Meeting — Detroit, Michigan October 15-17 — Motion + Power Technology Expo — Detroit, Michigan October 22 — Helical Gear Rating Committee Meeting — WebEx October 24 — Metallurgy and Materials Committee Meeting — WebEx

MOVING THE FUTURE.

THOUSANDS OF INNOVATIVE SOLUTIONS ALL UNDER ONE ROOF! REGISTER TODAY! OCTOBER 15–17, 2019 COBO CENTER | DETROIT, MICHIGAN

Owned by: Sponsoring organization: Co-located with:

August 2019 21 What’s new at Motion + Power Technology Expo?

Shop and compare the full range of power transmission solutions utilizing mechanical power transmission, pneumatics, hydraulics, electric motors, and drives.

At MPT Expo, you’ll see the entire power transmission supply chain — from forgings to machine tools to robotics. More than 300 exhibitors will show you the latest technologies and solutions.

Experience the brand-new MPT Conference, presented by NFPA and AGMA, with sessions presented by 16 speakers focusing on business topics and emerging technologies that all manufacturers will want to hear.

Participate in the inaugural Women’s Breakfast featuring Society of Women Engineers’ Fellow Stacey DelVecchio.

50 first-time exhibitors showcasing unique solutions.

Fluid Power Pavilion — your destination to learn if hydraulics and pneumatics could improve your project.

Emerging Technology Pavilion — provides a look at new, cutting-edge technology that is coming into the manufacturing space.

Young Professionals Reception — meet and mingle with the next generation of leaders.

The Heat Is On networking event — get the flavor of Detroit with regional food and drink.

who should attend?

CEOs Owners Presidents Engineers Marketing Consultants

22 gearsolutions.com AGMA’s Fall Technical Meeting This meeting brings together top researchers from across the globe who will provide the latest information on their peer-reviewed gear industry research. Network with industry experts, academics, and engineers; ask your burning questions; and see what’s next for the future of this industry.

FALL TECHNICAL MEETING NETWORKING AND EVENTS SCHEDULE

MONDAY, OCTOBER 14 | 1:00 PM – 8:00 PM TUESDAY, OCTOBER 15 | 7:00 AM – 5:00 PM WEDNESDAY, OCTOBER 16 | 7:00 AM – 5:00 PM

Each session will showcase five to six presenters sharing their highly technical knowledge of specific topics within the following research areas:

SESSION 1: Application, Design, and Rating

SESSION 2: Efficiency, Lubrication, Noise, and Vibration

SESSION 3: Materials and Heat Treatment

SESSION 4: Manufacturing, Inspection, and Quality Control

SESSION 5: Optimization, Gear Wear, and Failure

PRICING — INCLUDES ADMISSION TO THE EXHIBIT HALLS:

Member early bird: $995 Single session member: $295 Non-member early bird: $1,295 Single session non-member: $395 Member regular: $1,095 FTM Fun and Games Reception: $50 Non-member regular: $1,395

August 2019 23 NEW! MPT Conference

Each session includes a 45-minute presentation with an additional 15-minute Q&A portion.

the transfer of individual parts from suppliers to a manufacturing facility, which WEDNESDAY, OCTOBER 16 parts are on a specific automobile, the completion of an automobile on the assembly line, the delivery to the dealership, and all final sale information. While 9:00 AM – 10:00 AM tracking may be in place inside the manufacturer, blockchain could play a crucial Supply Chain: Jeff Newman, VP, Supply Chain Visibility Solution Sales, CalAmp role in transparency with suppliers and consumers. It could also streamline the tracking of parts, recalls, and repairs done by the service department. Improve In-Transit Visibility to Reduce Supply Chain Risk Advances in IoT technology provide greater visibility insights through real-time 2:00 PM – 3:00 PM data and monitoring to eliminate tracking blind spots across providers and modes. SM These smart sensors and devices continually log data in transit and transmit the 3D Printing: Kirk Rogers, PhD, Senior ADDvisor , The Barnes Group Advisors information to a cloud portal that is accessible anywhere. Processes and New Machines for 3D Printing Metal You will learn how a supply chain with embedded IoT technology provides this key The additive manufacturing/3D metal printing scene has exploded in the last data for making critical decisions on improving your operations and reducing risk. three years with several new players and several new technologies. Kirk will outline the seven different additive manufacturing technologies, as defined by ASTM 9:00 AM – 10:00 AM Committee F42. He will discuss how these technologies can be used to manufacture complex geometries and how they can reduce gear systems inertia through the use IIoT: Stacy Pease, Director of Customer Success, MachineMetrics of advanced designs that are difficult to manufacture conventionally. He will also Simplifying Industrial IoT for Discrete Manufacturers provide the most up-to-date information on new players from the eyes of someone The IoT revolution is picking up speed and as it does, it is changing the who has spent more than 20 years in this space. manufacturing world forever. Of the many manufacturers in pursuit of digitization, a large number are unlikely to succeed. According to a 2017 Cisco study, 74% of companies that begin an IoT initiative fail, leading to greater hesitation for 3:30 PM – 4:30 PM manufacturers to embark on their digital transformation journeys. So what’s the Supply Chain: Tom Rouse, Founder, Rouse Contract Consultants, LLC secret sauce to Industry 4.0 success? In this session, we explore how MachineMetrics is using data to drive down costs Effective Contract Negotiations: The Path to Commercial Success and increase revenue, as well as cover some of the ways data can be applied to drive with Large OE Customers your business ahead of your competition. Most importantly, this session will dispel In this session, you will learn to: some of the myths about the cloud and decode the buzzwords around “Industry 4.0” • Manage OE agreements to ensure profits are maximized and risks reduced so you can enter Industry 4.0 with confidence. • Improve your quotation process to help with future customer negotiations 10:30 AM – 11:30 AM • Identify all the value issues and risk issues of a customer agreement Market Info: Chloe Parkins, Fluid Power Specialist, Oxford Economics • Understand the roles of each person in effective contract negotiations Economic Outlook and Trends within the Industrial Fluid Power Market • Identify the priority points for negotiation The aim of this session is to provide an understanding of the economic backdrop • Understand the timing considerations in negotiating an OE sales agreement faced by industrial fluid power manufacturers and purchasers. We will first set the With this knowledge, you will be able to more effectively negotiate sales agreements scene with an overview of the global economy, highlighting key issues and trends with your large OE customers, thereby maintaining the business value, and reducing affecting overall industrial activity. Then we will drill down to the U.S. economy, risks over the life of the contract. giving a forecast outlook for the macro economy, including factors affecting investment and capital expenditure. We will cover a couple of relevant scenarios 3:30 PM – 4:30 PM around recent trends, events, and sources of risk. We will then delve deeper into the key drivers for industrial fluid power, focusing on key demand sectors that purchase Robotics: Alberto Moel, PhD, VP, Business Development, Veo Robotics and use fluid power equipment. The End of Fear: How Collaborative Industrial Robots Will Change Durable Goods Manufacturing 10:30 AM – 11:30 AM At present, most tasks in durable goods manufacturing are either fully manual Electric Drive Technology: John Bennett, VP and CTO, Meritor or fully automated — there is no safe in-between. But automating tasks that The Future of eMobility in the Commercial Vehicle Space are better done by humans and, conversely, adapting tasks that are better done by machines for human workers is suboptimal — it either over-complicates Commercial vehicles are currently undergoing a shift in powertrain technologies manufacturing in the case of full automation, or requires humans to perform tasks driven by the need for lower GHG emissions and the desire for lowest total cost for which they are ill-suited in the case of a fully manual process. of ownership. In this presentation, John will explore the current state of eMobility systems in commercial vehicles, the drivers and barriers for widescale adoption In this presentation, you will learn about the pressing need to make our existing of electric commercial vehicles, the future outlook of the various architectures of big, fast, and strong industrial robots collaborative. With modern sensors and electric drivetrains, and the impact to gearing technology in those architectures. computing platforms, we are now able to develop algorithms that allow industrial robots to understand where they are in a workcell, identify workpieces and the 2:00 PM – 3:00 PM people working around them, and take safe and effective actions. Blockchain: Joel Neidig, CEO and Co-Founder, SIMBA Chain THURSDAY, OCTOBER 17 Blockchain: The Future of Manufacturing 9:00 AM – 10:00 AM Blockchain has many manufacturing applications. Automotive supply chains are one of several use cases that will be discussed for this topic. A few appealing Market Info: Casey Selecman, Director — Advisory Services, IHS Markit applications of blockchain for automobile manufacturers are the ability to record The Evolution of the Automotive Powertrain

24 gearsolutions.com PRICING: Member/Non-member early bird: $295 EARLY BIRD DEADLINE IS SEPTEMBER 13 Member/Non-member regular: $395

Price includes admission to all 16 presentations, plus admission to the expo hall. MotionPowerExpo.com

By now, everyone has heard the noble truth about the future of powertrain 2:00 PM – 3:00 PM development around the globe: “This is the last generation of ICEs ever to be built!” While the shift to electric vehicles may be inevitable, the journey to make them a 3D Printing: Jeff Grabowski, Materials Specialist, QuesTek Innovations, LLC reality is going to be very complex and time-consuming. Is there enough capacity Materials Challenges and Solutions in Additive Manufacturing to build the battery packs required? Will oil-producing countries give up producing Much of the research in additive manufacturing (AM) has focused on a relatively a critical natural resource to protect the health of the planet? Will the technology small set of legacy and commodity alloys, such as stainless steel, Ti-6-4, and castable advance quickly enough to enable faster charging and greater range necessary to Al alloys. Often, the same alloy chemistry and standard heat treatment practices get customers to choose electrons over oil? This presentation will provide a critical developed for forged bar are used, resulting in material performance issues. assessment of the changing powertrain offerings and the potential impact on the This talk will provide recent project updates to optimize legacy alloys and design, industry. develop and deploy novel high-performance alloys for additive manufacturing processes, leveraging an Integrated Computational Materials Engineering (ICME) 9:00 AM – 10:00 AM approach and showing improvement over current commodity alloys. Alloys covered IIoT: Russ Waddell, Director, MTConnect will be relevant to gear and power applications. Standards for IIoT Interoperability 3:30 PM – 4:30 PM Manufacturing data and information systems are rapidly evolving to enable myriad new technologies around software and networking. Underlying this evolution Workforce: Todd Palmer, Founder and President, Diversified Industrial Staffing is a set of standards and protocols developed by industry, academia, research Hire Like Nobody’s Business organizations, and governments around the globe. Motion and power, like many Companies cannot locate enough of the talent they need today. This translates to other industry verticals, have unique needs and business requirements. Yet, there is missed deadlines and to company leaders trying to do more with less. The battle to much to be learned from previous standards development efforts and neighboring attract and retain top talent is going to continue. There is a solution. segments in manufacturing. In this presentation, you will learn: 10:30 AM – 11:30 AM • Culture is key — know why employees want to work for you and not someone else Workforce: Tony Velotta, Organizational Development Leader, Scot Forge • How to create a sustainable and repeatable model to source and attract top Workforce Development Using a Farm Team Approach talent resulting in a full talent pipeline There is a significant deficit in the number of workers needed and the number • How to screen out the contenders from the pretenders with interview questions available to most companies. Scot Forge Company has a program to develop designed to dig deep the future workforce to be ready when needed similar to major league sports • How to use the People Analyzer to decide if an employee isn’t the right fit for your teams using a farm team concept. The farm team is a ready-to-go supply of talent culture that is called to the big league when needed. Scot Forge starts with high school students and develops their skills and, most importantly, their culture, to be hired full-time when ready and needed. The program consists of two key components: 3:30 PM – 4:30 PM organizational development and employee ownership that involves high school Robotics: Rick Maxwell, Collaborative Robot Team, FANUC America student learners, college internships, apprenticeships, associate and bachelor Corporation degrees, and in-house training such as leadership, supply chain management, and Collaborative Operation in Industry Today sales training programs. Collaborative operation and more generally the collaborative robot are very 10:30 AM – 11:30 AM popular topics in the automation industry. In order to successfully implement and use collaborative technology, it is important to understand what collaborative Electric Drive Technology: Jeff Hemphill, CTO, Schaeffler operation is and how it can fit into your facility. Looking at the safety standards for Losing Teeth? The Future of Gear Trains in the Age of collaborative operation is a great start; however it is highly recommended to review Electrification the technical report guidelines for integrating collaborative operations in the RIA The rate of electrification seems to be accelerating every day. Major OEMs make TR15.606 and validating force and power limited collaborative operation in the RIA regular announcements about battery electric vehicles and Tesla continues to TR15.806. Choosing a good application for your first collaborative robot will help disrupt its segments. But where does that leave a gear supplier or engineer? In this integrate this technology into your factory and introduce your employees to the session, we’ll take a look at some of the new challenges and new applications and exciting world of shared work spaces between people and robots. see where the gears and bearings of the future will be deployed.

2:00 PM – 3:00 PM Cybersecurity: James McQuiggan, CISSP, Chapter President, (ISC)2 Central Florida Chapter Cybersecurity Hygiene in Motion When it comes to hygiene, we grew up understanding what is good hygiene, washing our hands before dinner, brushing our teeth before bed, and taking a shower at least every other day. In cybersecurity, similar hygiene can be applied to our daily lives that can help not only at home, but also in the places we work. Within the company and as it relates to cybersecurity, leaders are unsure of that hygiene in the standards they need to follow, what technology they need to purchase, and how to protect against an attack. In motion or standing still, there are simple things that we can do to protect ourselves online, at home, and at the office.

August 2019 25 Education Courses Free pass to both exhibit halls when you register for any education course. Free pass to both exhibit halls when you register for any education course.

Technical Overview of Automotive Registration Fee: is offering this course on rolling element bearings DifferentialsTechnical Overview of Automotive RegistrationEarly Bird, through Fee: September 13, 2019: isfor offering those involved this course in industrial on rolling equipment element bearings design, DifferentialsInstructor: William Mark McVea, KBE+, Inc. EarlyMember: Bird, $295 through September 13, 2019: forreliability, those involved and maintenance. in industrial It equipmentwill include design, a basic Member:Non-Member: $295 $395 reliability,overview of and rolling maintenance. bearings, theirIt will selection, include a precision basic TUESDAY,Instructor: William OCTOBER Mark 15 McVea, KBE+, Inc. Non-Member:After September $395 13, 2019: overviewand mounting of rolling considerations, bearings, their service selection, life estimation, precision 8:00 AM – 12:00 PM TUESDAY, OCTOBER 15 AfterMember: September $350 13, 2019: and mountinglubrication-related considerations, influences. service A hands-onlife estimation, damage 8:00 AM – 12:00 PM This seminar will provide insight into automotive Member:Non-Member: $350 $450 andanalysis lubrication-related session will be influences.the featured Aportion hands-on of thisdamage Thisdifferential seminar technologies will provide —insight specifically, into automotive the intended Non-Member: $450 analysisprogram. session will be the featured portion of this differentialfunction, issues technologies with the common— specifically, differential the intended types program.Registration Fee: function,(i.e., open issues differential), with the the common concept differential of traction types aiding Overview of Fluid Power Components and RegistrationEarly Bird, through Fee: September 13, 2019: (i.e.,differentials open differential), and the difference the concept between of traction passive aiding SystemsOverview of Fluid Power Components and EarlyMember: Bird, $295 through September 13, 2019: differentialsmechanical andand activethe difference electronic, between and finally passive an SystemsPresented by: Thomas Wanke, CFPE Director, Member:Non-Member: $295 $395 mechanicaloverview of theand design active requirementselectronic, and and finally common an PresentedFluid Power by: Industrial Thomas ConsortiumWanke, CFPE and Director, Industry Non-Member:After September $395 13, 2019: overviewmanufacturing of the nuancesdesign requirements specific to differentialand common gears. FluidRelations, Power MSOE Industrial Consortium and Industry AfterMember: September $350 13, 2019: Registrationmanufacturing Fee: nuances specific to differential gears. Relations, MSOE TUESDAY, OCTOBER 15 Member:Non-Member: $350 $450 RegistrationEarly Bird, through Fee: September 13, 2019: TUESDAY,1:00 PM – 5:00OCTOBER PM 15 Non-Member: $450 EarlyMember: Bird, $295 through September 13, 2019: 1:00 PM – 5:00 PM Member:Non-Member: $295 $395 This introductory-level course will cover the benefits Fundamental Understanding of Electro Non-Member:After September $395 13, 2019: Thisand challengesintroductory-level of using course fluid willpower cover systems the benefits for FluidFundamental Power Technology Understanding of Electro AfterMember: September $350 13, 2019: andpower challenges transmission of using and fluidmotion power control. systems Physical for FluidPresented Power by: Dr.Technology Medhat Khalil, CHFPS, CFAPI, Member:Non-Member: $350 $450 powerlaws that transmission govern how and and motion why fluid control. power Physical systems PresentedDirector of by: Professional Dr. Medhat Education Khalil, CHFPS, and Research CFAPI, Non-Member: $450 lawsfunction that will govern be discussed. how and whyIndividual fluid componentspower systems that DirectorDevelopment of Professional Education and Research functioncomprise will a fluid be discussed. power system, Individual including components their design, that Development Supply Chain Management compriseconstruction, a fluid and poweroperational system, characteristics, including their will design, WEDNESDAY, OCTOBER 16 SupplyInstructors: Chain Dr. Justin Management Jones and Keyvan Gerami, construction,be presented. andISO operationalsymbology usedcharacteristics, for representing will 8:00WEDNESDAY, AM – 12:00 OCTOBER PM 16 8:00 AM – 12:00 PM Instructors:Ranken Technical Dr. Justin College Jones and Keyvan Gerami, beindividual presented. components ISO symbology will be usedcovered. for representing The course will This seminar briefly introduces electro fluid power individualcollimate withcomponents a brief overview will be covered. of circuit The architectures. course will TUESDAY,Ranken Technical OCTOBER College 15 Thistechnology seminar and briefly its outstanding introduces featureselectro fluid as compared power collimate with a brief overview of circuit architectures. TUESDAY,8:00 AM – OCTOBER12:00 PM 15 Registration Fee: technologyto the other and power its outstandingtransmission features and motion as compared RegistrationEarly Bird, through Fee: September 13, 2019: tocontrol the other systems. power Fundamental transmission knowledge and motion about This8:00 course AM – provides 12:00 PM an overview on knowledge of EarlyMember: Bird, $295 through September 13, 2019: controlthe most systems. common Fundamental types of electrohydraulic knowledge about and Thissupply course chain provides management an overview concepts, on knowledgecomponents, of Member:Non-Member: $295 $395 theelectropneumatic most common valves types ofwill electrohydraulic be covered. Various and supplyand principles. chain management An introduction concepts, to the components, competitive Non-Member:After September $395 13, 2019: electropneumaticcriteria to select a valves specific will valve be covered. for an application,Various andadvantages principles. needed An introduction by skilled individuals to the competitive to design, AfterMember: September $350 13, 2019: criteriaincluding to valveselect type, a specific spool design,valve for operating an application, advantagesexecute, and needed manage by their skilled supply individuals chain. to design, Member:Non-Member: $350 $450 includingconditions, valve and type,static spool and dynamicdesign, operating characteristics, will execute, and manage their supply chain. Registration Fee: Non-Member: $450 conditions,be discussed. and This static seminar and dynamicalso covers characteristics, various system- will RegistrationEarly Bird, through Fee: September 13, 2019: level control loops architectures and tuning methods Technical Overview of Automotive be discussed. This seminar also covers various system- EarlyMember: Bird, $295 through September 13, 2019: levelfor system control performance. loops architectures and tuning methods Member:Non-Member: $295 $395 PowertrainTechnical Overview Lubricants of Automotive Registrationfor system performance. Fee: Non-Member:After September $395 13, 2019: PowertrainInstructor: William Lubricants Mark McVea, KBE+, Inc. RegistrationEarly Bird, through Fee: September 13, 2019: AfterMember: September $350 13, 2019: Instructor: William Mark McVea, KBE+, Inc. TUESDAY, OCTOBER 15 EarlyMember: Bird, $295 through September 13, 2019: Member:Non-Member: $350 $450 TUESDAY,1:00 PM – 5:00OCTOBER PM 15 Member:Non-Member: $295 $395 Non-Member: $450 This1:00 course PM – will5:00 provide PM a brief review of all common Non-Member:After September $395 13, 2019: Thistransmission course will technologies provide a brief as a reviewprecursor of all to common AfterMember: September $350 13, 2019: Hydraulic Fluid Properties, Efficiency, and transmissiondevelopment technologiesof the functional as a requirements precursor to of the Member:Non-Member: $350 $450 ContaminationHydraulic Fluid ControlProperties, Efficiency, and developmentlubricants for ofeach the offunctional the common requirements transmission of the Non-Member: $450 ContaminationPresented by: Paul ControlMichael, Research Chemist, lubricantstechnologies, for endingeach of with the commona detailed transmission discussion of PresentedMSOE by: Paul Michael, Research Chemist, technologies,lubricant theory, ending composition, with a detailed and application. discussion of Gearbox Field Inspection — Load MSOE Registrationlubricant theory, Fee: composition, and application. Distribution,Gearbox Field Lubrication, Inspection —and Load Condition TUESDAY, OCTOBER 15 Distribution, Lubrication, and Condition TUESDAY,8:00 AM – OCTOBER12:00 PM 15 RegistrationEarly Bird, through Fee: September 13, 2019: Monitoring 8:00 AM – 12:00 PM EarlyMember: Bird, $295 through September 13, 2019: MonitoringInstructors: John B. Amendola, John B. Amendola In this seminar, participants will learn about the Member:Non-Member: $295 $395 Instructors:III, and Dereck John Yatzook, B. Amendola, Artec Machine John B. AmendolaSystems Incomposition this seminar, of oils,participants the properties will learn of lubricants, about the Non-Member:After September $395 13, 2019: WEDNESDAY,III, and Dereck Yatzook, OCTOBER Artec 16 Machine Systems compositionand how hydraulic of oils, fluids the properties can affect of lubricants,machine AfterMember: September $350 13, 2019: WEDNESDAY,8:00 AM – 12:00 OCTOBER PM 16 andperformance. how hydraulic Conventional, fluids can multi-grade, affect machine synthetic, Member:Non-Member: $350 $450 8:00 AM – 12:00 PM performance.and biodegradable Conventional, fluids will multi-grade, be discussed. synthetic, Research Non-Member: $450 Gears can fail due to various damage patterns. andstudies biodegradable examining fluid fluids efficiency will be discussed. effects in Researchhydraulic GearsIn this canseminar, fail due the to combined various damageinfluence patterns. of shaft studiesmotors, examiningas well as fluidpiston efficiency and gear pumpseffects inwill hydraulic be Why Bearings Are Damaged Inmisalignments this seminar, and the gearcombined lead crowninfluence on load of shaft motors,presented. as Thewell principlesas piston andof oil gear analysis pumps and will filter be WhyPresented Bearings by: ABMA Are Damaged misalignmentsdistribution and and tooth gear bending lead crown stresses on loadis applied to presented.selection will The be principles outlined. ofThe oil seminar analysis will and conclude filter distributionreal-world circumstances. and tooth bending Both stressesthe operator is applied and the to TUESDAY,Presented by: OCTOBER ABMA 15 selectionwith case willstudies be outlined. that demonstrate The seminar how will filter conclude debris real-worlddesigner must circumstances. consider gear Both tribology. the operator Consequences and the TUESDAY,1:00 PM – 5:00OCTOBER PM 15 withanalysis case can studies be used that to demonstrate troubleshoot how hydraulic filter debrissystem designerof inadequate must lubricationconsider gear and tribology. how to establish Consequences 1:00 PM – 5:00 PM analysiscontamination can be control used to problems. troubleshoot hydraulic system The American Bearing Manufacturers Association ofongoing inadequate maintenance lubrication procedures and how will to establishbe covered. contamination control problems. The American Bearing Manufacturers Association ongoing maintenance procedures will be covered.

26 gearsolutions.com Gearbox diagnostics and service are critical to the overview of standard gearing nomenclature, gear improved gear performance. This course, developed field inspection process and will also be explored in involute geometry, inspection procedures, and much jointly by AGMA and ASM International, will provide depth. more. an overview of materials selection and heat treatment Registration Fee: Registration Fee: of gears. Early Bird, through September 13, 2019: Early Bird, through September 13, 2019: Registration Fee: Member: $295 Member: $650 Early Bird, through September 13, 2019: Non-Member: $395 Non-Member: $780 Member: $445 After September 13, 2019: After September 13, 2019: Non-Member: $575 Member: $350 Member: $750 After September 13, 2019: Non-Member: $450 Non-Member: $880 Member: $525 Non-Member: $655

Reverse Gear System Engineering —Why, Taming Tooth Deflections: The Case for When, and How Profile Modifications Loaded Tooth Contact Instructor: Raymond Drago, P.E., Drive Systems Instructor: Raymond Drago, P.E., Drive Systems Instructor: Terry Klaves Technology Technology THURSDAY, OCTOBER 17 WEDNESDAY, OCTOBER 16 THURSDAY, OCTOBER 17 1:00 PM – 5:00 PM 8:00 AM – 5:00 PM 8:00 AM – 12:00 PM This seminar will calculate and demonstrate the Reverse engineering a gear system is not too unusual Pack your “bag of tricks” with knowledge of how effect that shaft bending, torsional windup, and tooth of a task. In many cases — but not all — the process teeth deflect, what involute interference really is, deflections have on loaded tooth contact on various goes fairly well; thus it is easy to become complacent. the potential consequences of inadequate profile configurations of parallel shaft spur and helical It is important, however, to fully understand the modifications, and the difference between tip relief, gearing. With the loaded tooth and shaft deflections process and the best practice procedure for reverse flank relief, and fully modified profiles. Students learn identified in real-life examples, tooth helix and profile engineering a gear system. Failure to fully follow best how to calculate tooth deflections under load and, modifications will be developed that, when properly practice can result, at best, in an unhappy gear user, most importantly, how to modify a gear set properly manufactured and applied, will significantly improve but in the worst case it can lead to very expensive, to eliminate involute interference. Finally, we will loaded tooth mesh contact to support realistic load time-consuming, and reputation-damaging litigation. examine the optimum drawing definitions for profile distribution factors used in rating of parallel shaft We will discuss the basic types of reverse engineering. modifications and how to interpret involute inspection spur and helical gears. The process involves the The need for understanding the operation of the charts to determine if the drawing’s required profile application of commercially available software that system in which the gears will be used, the conditions modifications have actually been produced on the models the loaded gear mesh in FEA. This evaluation that led to the need for the project, and especially the gear set. and corrective action will promote optimization of power density with predictable fatigue life. specific nature of the failure that occurred (if that is Registration Fee: the reason for the project) are key and often ignored Early Bird, through September 13, 2019: Registration Fee: elements of the process. Member: $295 Early Bird, through September 13, 2019: Registration Fee: Non-Member: $395 Member: $295 Early Bird, through September 13, 2019: After September 13, 2019: Non-Member: $395 Member: $445 Member: $350 After September 13, 2019: Non-Member: $575 Non-Member: $450 Member: $350 After September 13, 2019: Non-Member: $450 Member: $525 Non-Member: $655 Materials Selection and Heat Treatment of Gears Presented by: AGMA and ASM International Basics of Gearing THURSDAY, OCTOBER 17 Instructor: William Mark McVea, KBE+, Inc. 8:00 AM – 5:00 PM WEDNESDAY, OCTOBER 16, Because of their unique contribution to the operation THURSDAY, OCTOBER 17 8:00 AM – 5:00 PM of so many machines and mechanical devices, gears have received special attention from the technical Dramatically improve your knowledge and productivity community for more than two millennia. New through Basics of Gearing. This course will be presented developments in gear technology, particularly from in a two-day format and will give you a comprehensive the materials and heat treatment perspectives, have

EXHIBIT HALL HOURS

TUESDAY, OCTOBER 15 | 9:00 AM – 6:00 PM WEDNESDAY, OCTOBER 16 | 9:00 AM – 5:00 PM THURSDAY, OCTOBER 17 | 9:00 AM – 4:00 PM

August 2019 27 Exciting events TO NETWORK AND BUILD YOUR COMMUNITY

Hosted by AGMA, NFPA, and ASM, open to all registrants of both events.

FTM FUN AND GAMES RECEPTION MONDAY, OCTOBER 14 | 6:00 PM – 8:30 PM MPT Expo attendees are invited to join AGMA Fall Technical Meeting attendees at our FTM Fun and Games Reception at Punch Bowl Social Detroit. Enjoy food and drinks with your colleagues while participating in fun activities such as bowling, darts, karaoke, and arcade games. A great way to kick off a busy week at MPT Expo! FREE for FTM attendees $50 for all other attendees

OPENING NIGHT WELCOME RECEPTION TUESDAY, OCTOBER 15 | 5:00 PM – 6:00 PM Don’t miss this meet-and-greet event right on the show floor! FREE for all attendees Two drink tickets included with registration.

YOUNG PROFESSIONALS RECEPTION AT MPT EXPO TUESDAY, OCTOBER 15 | 6:00 PM – 8:00 PM The evening will be a great opportunity for all those business professionals 35 and under to network and engage in industry discussion while enjoying food drinks and entertainment. $15/person

THE HEAT IS ON WEDNESDAY, OCTOBER 16 | 6:30 PM – 9:30 PM Join your fellow Heat Treat and MPT attendees during our premier networking event, “The Heat Is On.” This special evening will capture the heart of Detroit and all attendees with live music, a tempting array of Detroit-inspired food, craft beer, and a few “hot” surprises! Member: $85 Non-Member: $95

WOMEN IN MANUFACTURING BREAKFAST THURSDAY, OCTOBER 17 | 7:30 AM – 8:30 AM This breakfast will allow women in all sectors of manufacturing and power transmission to share thoughts and ideas about industry innovation. Hear our guest speaker share her experience and leave with ideas and a fun giveaway! Featured Speaker: Stacey M. DelVecchio, President, StaceyD Consulting, F. SWE, Secretary of Women in Engineering Committee for WFEO $15/person

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KAPP Technologies 2870 Wilderness Place Boulder, CO 80301 kapp-niles.com [email protected] (303) 447-1130 August 2019 29

082019_KappAd_ZE_FullPage_GS 2.0.indd 1 6/23/2019 11:21:46 AM WILLIAM P. NEBIOLO PRODUCT MANAGER  MATERIALS  MATTER REM SURFACE ENGINEERING

Selecting media for optimum vibe bowl gear finishing Choosing the best media depends on structure Finally, spherical media offers the least efficient contact pattern possible, contacting a tooth flank only at a single point. Spherical and shape of the tooth flank, and whether media should be considered a media of last resort if no other shape media components should be abrasive, can be employed. Spherical media typically results in a longer pro- non-abrasive, or a blend. cessing time than the other two contact patterns. MEDIA COMPOSITION CONSIDERATIONS he second in our multi-part series on vibratory processing of gears The two main components in the make-up of an abrasive ceramic Tis focused on the selection of media that will be used to improve media are aluminum oxide grit and clay. Blended together with sev- gear surface quality. eral other ingredients, the media is extruded through a die, cut to length, then kiln-fired. The kiln firing operation converts the clay MEDIA CONTACT PATTERN VS. THE FORM to ceramic. Assorted clay types that may be used are river, bentonite, OF THE SURFACE TO BE CONTACTED kaolin, porcelain and china clay. After firing we can consider the When gear finishing callouts require a final tooth flank Ra that is resultant ceramic as the binder that holds the media together. lower than the as-shaved, as-lapped, or as-ground surface, a typical When considering media composition, we are trying to deter- response is to use vibratory abrasive ceramic media for generic tooth mine which media to use based on the ratio of the abrasive grit finishing to an Ra = 8–20 μinches, or high-density, non-abrasive media to the ratio of the clay. As the percentage of abrasive increases in for an isotropic superfinish of Ra ≤ 4 μinches. the composition, the proportion of ceramic must consequentially Size, shape, and composition of media used depend on the mor- decrease. Since the ceramic is the binder that holds the media phological form of the gear teeth and the final Ra value required. together, a media with less binder present has a higher attrition Abrasive ceramic media typically contains aluminum oxide abrasive rate. Attrition is the rate at which media decreases in volume as grit and mechanically abrades the surface to improve the Ra value. a function of processing time. A high abrasive media with a high In isotropic superfinishing, a chemical accelerator is employed to attrition rate decomposes rapidly, contributing more loose abrasive create a soft conversion coating that is wiped from the tooth flank into the vibratory mass. This increases abrasive action, decreases surface with the high-density non-abrasive media. processing time, and produces a matte final finish. An attrition Vibratory processing is optimized when the shape of the media rate of 2 percent per hour is typical. closely matches the shape of the tooth flank. The most efficient con- Media of different compositions attrit at different rates. High tact pattern is plane-to-plane. When the flat face of the tooth flank abrasive content media will finish parts rapidly, generating a final is matched with a media having a flat-face(s), then the maximum Ra value 15-18 μinches. Lower abrasive content media will finish at surface area possible is contacted per unit of processing time. Plane- a slower speed, producing an Ra value in the 9-12 μinch range. The shaped media examples are straight and angle cut triangles, tetra- higher the media’s attrition rate, the greater the volume of sludge it pyramids, and the base of a cone. will produce per unit time. Circular-shaped media, such as cylinders, offer a less efficient Isotropic superfinishing employs high-density, non-abrasive tangent-line contact pattern. Such contact isn’t planar, but linear. media to wipe, not abrade, surface asperities when used with a Much less surface area is contacted per unit of processing time and chemistry that forms a soft conversion coating. A non-abrasive media the cycle is usually extended. Media offering linear contact patters leaves a mirror-reflective surface on steel surfaces hardened to Rc ≥ are cylinders, or the side of a cone. 40. The attrition of this media is nearly nil, typically 0.008 percent per hour. Final Ra values are ≤ 4 μinches are usually achieved, and a Aluminum oxide grit used in final step burnishing step removes the conversion coating to leave abrasive ceramic media. a clean final finish. WHEN TO USE A BLEND OF MEDIA Low DP tooth patterns are easier to refine as the media can more uniformly contact the tooth f lank, addendum to dedendum. Tighter pitch pattern gears may be better finished using a media blend. Tooth addendums project into the media mass and are more easily recessed than dedendums. Therefore, metal removal rates vary from addendum to dedendum. To equilibrate metal removal from top land to root, consider blending two or more media types. Smallish, high- density media with a density of 125 lbs/ft3 falls to the root where its weight is advantageous in applying more inertial force in this recessed location.

30 gearsolutions.com Large, bulky media affects the part surface more forcefully and does more work per unit run time. Smaller media affects the part surface less forcefully, but encapsulates the part uniformly, offering cushioning and a higher quality final finish.

Inversely, a large, bulky, lightweight media of polyester plastic more work per unit run time. A large, bulky media does not fill a vol- composition will bring to bear much less force to the location it con- ume efficiently, resulting in large interstitial void spaces that drain tacts. With a density of just 65 lbs/ft3, coupled with a bulky-shape, fluid efficiently during vibratory finishing. this media only contacts the gear’s topland and addendum locations. Smaller media affects the part surface less forcefully, but encap- Concomitantly, its light density applies a much lower inertial force sulates the part uniformly, offering cushioning and a higher qual- in these easily contacted areas, thereby reducing the metal removal ity final finish. Smaller media packs tighter to fill a void space rate there and permitting it to match the high-density media metal efficiently. There are more void spaces, but they are very small in removal rate in the dedendum and root. size and retain fluid in the bowl due to surface tension. This slows mass roll speed and increases the propensity to form fluid geysers. FLUID RETENTION IN THE VIBRATORY BOWL A fluid extraction pump is usually a necessity when small media is Large, bulky media affects the part surface more forcefully and does employed.

ABOUT THE AUTHOR

William (Bill) P. Nebiolo received a B.A. from The University of Connecticut and an M.S. in environmental sciences from Long Island University. He has been with REM Surface Engineering since 1989 and currently serves as a sales engineer and as REM’s product manager. Since 1978, Nebiolo has been an active member in the National Association for Surface Finishing (NASF) where he has represented the Connecticut chapter as an NASF national delegate and is the 2010, 2014, and 2015 recipient of the NASF National Award of Merit. From 1996 to 2000, he served as one of SME’s Mass Finishing technical training program instructors. He has published and presented dozens of technical papers and is the author of the SME Mass Finishing Training Book. Nebiolo can be reached at [email protected].

August 2019 31 BRIAN DENGEL TOOTH  TIPS GENERAL MANAGER KHK-USA

What do you do? I sell gears! What reaction do you get at a cocktail party gears typically do all of their good work behind the scenes. It is only when they fail that they become exposed. This is when most people when you try to explain your profession? become aware of the gears around them in everyday life. If I do find a sympathetic ear to listen to me describe my career as his year, my 11-year-old daughter asked me to be one of the parents a gear engineer, the conversation will eventually turn to the avail- Twho presented their profession on career day. She is very proud of ability of 3D CAD models and how they can simplify and prove out a her dad and wanted to show all of her classmates the cool job that her design before producing physical gears. With the use of 3D printing, dad had. After all, being a gear engineer is just as cool as being a fire- generating a physical prototype is becoming easier. However, just fighter, or a police officer, or a teacher, or a social worker, or an ortho- because you can draw something in CAD and have it 3D printed, dontist. The biggest difference between being a gear engineer and doesn’t mean that it can be produced using traditional gear machin- all of these other professions is that the others are all public-facing ery. professions that people have a good understanding of, whereas they When you were a child, I am certain that you drew pictures that have little or no understanding of what a gear engineer is or does. represented ideas that you had but were not possible in real life. Like I get the same response from both adults and children when I the picture that you drew of your family. Mom and Dad, the cat, the explain that I sell gears and gear designs as a career. They all say, dog, and your siblings, all standing in front of your house. In the “Oh, like for cars!” When I start to explain that I don’t sell gears picture Mom and Dad were almost the same height as the house. for automotive applications but for ordinary industrial applications, Either you had very tall parents or you lived in a very short house. In their eyes glaze over, and they just nod their head. reality, neither was true. You just sketched out your thoughts, and When I presented to the sixth-graders this year, they answered the concept of scale was absent from your young mind. just like their parents. The only concept of gearing that they knew Similar situations occur within CAD designs. It is certainly pos - was automotive in nature. It was my responsibility to educate them sible to draw a gear with a 20mm hub that has an 18mm bore, but is and expand their understanding. My first attempt at bringing a real- it practical to have a 1mm wall thickness on the hub? How could you world gearing example to their attention was to show them the inner machine this and maintain the concentricity of the hub? How about workings of the mechanical pencil sharpener. It contains two conical a gear with a Module 6 pitch and a face width of 4mm? It might look gears that intersect in such a way that they grind the pencil into a OK in CAD, but it wouldn’t be practical in a real application. sharp point. Unfortunately, they no longer have mechanical pen- I have always enjoyed being a gear engineer because each project cil sharpeners in the classroom, as the students all use mechanical brings unique challenges, but sometimes I wish that it was easier to pencils these days. My next example was the gearing that operates explain what I do and where gears affect our everyday lives. the local drawbridge leading to the beach. They all knew the bridge, but as the gears are hidden from view, they couldn’t visualize that example either. Next on my list was the conveyor belt used on the self-checkout at the local supermarket. I asked the students how they thought the belt was able to move. This finally clicked in their heads. They understood that a motor created the motion and a gear train moved that motion to the conveyor. There are so many examples of gearing in everyday life, but they are mostly hidden and therefore go unnoticed. It could be the eleva- tor that takes you up to the eighth floor of the hotel or the escalator that takes you up to the second floor of the mall. It could be the cash dispenser at the ATM or the postage machine in the post office lobby. It could be the electric can opener in your kitchen or the paper shred- der in your den. Each of these items has gears inside of them, and their job would be impossible to do without gearing. For each gear application, a gear engineer has used their knowledge of physics, strength of materials, thermodynamics, stress, strain, and mathematics to design the optimum gear for the usage conditions assumed for the project. When the gear is used as designed, the general public never realizes that it is working. Unfortunately,

ABOUT THE AUTHOR Brian Dengel is general manager of KHK-USA, which is based in Mineola, New York. Go online to www.khkgears.us

32 gearsolutions.com ARE YOU MAXIMIZING YOUR EXPOSURE? Connect your company to the gear industry with a storefront in the Gear Solutions Community. Storefronts paint a portrait of your company with a 500-word description and include your logo, website link, phone number, email addresses, and videos. Your social media pages such as Twitter and Facebook are integrated with live updates, which may also be re-posted through our social media feeds. With a community storefront, your company also receives a premium listing in the annual Buyer’s Guide published each November. Premium listings feature graphic treatments to draw more attention to your company.

JOIN THE GEAR SOLUTIONS For information on how you can participate in the COMMUNITY GearSolutions.com community storefront, contact FOR ONLY [email protected]. $ 350 Chad Morrison – associate publisher PER YEAR 800.366.2185 x 202

August 2019 33 D. SCOTT MACKENZIE, PH.D., FASM HOT SENIOR RESEARCH SCIENTIST–METALLURGY  SEAT HOUGHTON INTERNATIONAL INC.

Back to basics with tempering (Part II) Fundamental methodology for calculating tempering times and temperatures for steels can simplify the empirical determination of appropriate temperatures to use to process a new part.

fter a part has been austenitized and quenched, it must be tem- Apered. As was discussed previously [1], the purpose of tempering is to relieve the transformational residual stresses from quenching, and to transform the brittle martensite to tougher tempered martensite. It can also convert any remaining austenite to tempered martensite or bainite. One of the issues facing the heat treater is determining the time and temperature to achieve the desired hardness or mechanical properties. Most data is similar to Figure 1, which shows typical Figure 1: Typical hardness after water quenching to achieve fully martensitic hardness after quenching a 25mm round to full as-quenched hard- structure, then tempering for one hour. Data was obtained by quenching 25 mm ness [2]. round bars. There are several methods of determining the appropriate time and temperature for tempering. One method of determining time and temperature is described by Canale et al [3]. As a first step, the desired temperature is calculated using the equation developed by Just [4].

Where Tt is the absolute temperature of tempering (°K) – valid in the range of 390° - 660°C; Hq is the as-quenched hardness (HRC); Ht is the required hardness after tempering (HRC); and S is the ratio of the as-quenched hardness versus the maximum hardness (S = Hq measured/Hmax). The total tempering time including heat-up and soaking time is calculated from [5] [6]: Figure 2: Hardness of tempered martensite in Fe-C steel after tempering for one hour. where t is the time in minutes, m is the mass of the load (kg), A is the total surface area (m3), and a and b are constants that are developed empirically for each furnace used. This method requires significant T1 and t1 are the known temperatures and times for T2 and t2 are empirical work to be done to evaluate each possible furnace and alloy the desired temperatures and times. C is a constant, which varies by and load combination. steel grade, and ranges from 15-22. It is generally accepted to have a Tempering is dependent on time, temperature carbon content, value of 20, but some authors recommend a value 18 [1]. Table 1 shows and alloying elements. Alloying elements retard softening during Larson-Miller values of C for various alloys. tempering, and change the kinetics of tempering [7]. Figure 2 shows One of the problems with the use of the Larson-Miller equation the hardness of iron-carbon alloys tempered at various temperatures. is that it assumes an isothermal process. However, the process of One relationship that has been used successfully in determin- tempering involves heating the parts to temperature, holding at the ing the time for tempering is the Holloman-Jaffe equation [8], also desired temperature for the desired amount of time, and cooling the known as the Larson-Miller equation [9]: parts to room temperature. During the heating of parts, there will be

34 gearsolutions.com [ 6 ] B. Lisicic and T. Filetin, “Computer-aided determination of the process parameters for hardening and tempering structural steels,” Heat treatment of Metals, vol. 3, pp. 62-66, 1987.

[ 7 ] R. A. Grange, C. R. Hribal and L. F. Porter, “Hardness of Tempered Martensite in Carbon and Low Alloy Steels,” Met. Trans. A, vol. 8A, pp. 1775-1785, 1977.

[ 8 ] J. H. Holloman and J. H. Jaffe, “Time-temperatures relations in tempering steel,” Trans. American Inst. Mining and Met. Eng., vol. 162, pp. 223-249, 1945.

[ 9 ] F. R. Larson and J. Miller, “A time-temperature relationship for rupture and creep stresses,” Trans. ASME, vol. 74, pp. 765-775, 1952.

[ 10 ] R. A. Grange and R. W. Baughman, “Hardness of tempered martensite in carbon and low alloy steels,” Trans. ASM, vol. XLVIII, pp. 165-197, 1956.

[ 11 ] T. F. Gulvin, D. Scott, D. M. Haddrill and J. Glen, “Paper no. 621 – The Table 1: Larson-Miller values for the constant C for different materials [3]. influence of stress relief on the properties of C and C-Mn pressure-vessel plate steels,” J. West Scotland Iron and Steel Inst., vol. 80, pp. 149-175, 1972-1973. some transformation of the martensite to temperature martensite. [ 12 ] C. Ulff, “Effect of stress-relief annealing on the mechanical properties of This is also true of the cooling process. To overcome these issues, steel grades for pressure vessels,” Jem-kontorets annaler, vol. 154, no. 2, the effect of heating and cooling was examined by Gulvin et al., pp. 53-64, 1970. using the Larson-Miller equation to determine appropriate times for stress-relieving. An additional equivalent time Teq at the tempering temperature, based on linear heating and cooling, was calculated [11] [12]. ABOUT THE AUTHOR D. Scott MacKenzie, Ph.D., FASM, is senior research scientist- metallurgy at Houghton International Inc. For more information, go to www.houghtonintl.com. where T is the tempering temperature in °K, and k is the heating or cooling rate in °K/hr. The total time during tempering is then: YOUR INDUSTRY NEWS SOURCE

From the above equations, the tempering time can be estimated Gear Solutions magazine has been the most trusted if one time-temperature relationship is known. source for information and technical knowledge in the CONCLUSIONS gear manufacturing industry for more than 15 years. In this short article, the basic methodology for calculating different Each issue, Gear Solutions offers its readers the latest, most tempering times and temperatures for steels was provided. While valuable content available from companies, large and small, somewhat math intensive, it can simplify the empirical determina- as well as critical thoughts on what this information means tion of appropriate temperatures to use when processing a new part. for the future of the gear manufacturing industry. Should you have any questions regarding these calculations, or Best of all, it’s free to you. All you need to do is subscribe. to suggest a future heat-treating article, please contact the author at

the email address at the end of the article. GEAR SOLUTIONS MAGAZINE MAGAZINE SOLUTIONS GEAR

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REFERENCES

Your Resource for Machines, Services, and Tooling for the Gear Industry [ 1 ] D. S. MacKenzie, “Back to Basics - Tempering,” Gear Solutions, pp. 28-29, Your Resource for Machines, Services, and Tooling for the Gear Industry March 2019.

ISSUE FOCUS

[ 2 ] American Society for Metals, Heat Treaters Guide Standard Practice and ISSUE FOCUS

THE ROOT CAUSE FOR GEAR NOISE EXCITATION NOISE GEAR FOR CAUSE ROOT THE Bevel Gears | Plastic Gears Procedures for Steel, Metals Park, OH: ASM International, 1982, pp. 423- Cutting Tools | Workholding INCREASING STATIC FRICTION WITH LASER THE ROOT CAUSE FOR

426. INCREASING GEAR NOISE

[ 3 ] STATIC FRICTION L. Canale, X. Yao, J. Gu and G. E. Totten, “A historical review of steel tem- EXCITATION WITH LASER pering parameters,” Int. J. Microstructure and Materials Properties, vol. 3, COMPANY SUBSCRIBE FOR FREE PROFILE COMPANY no. 4-5, pp. 474-525, 2008. PROFILE PISELLI ENTERPRISES www.gearsolutions.comWEILER ABRASIVES

[ 4 ] E. Just, “‘Vergüten. Werkstoffbeeinflussung durch Härten und Anlassen’,” DECEMBER 2018 DECEMBER

VDI Berichte, vol. 256, pp. 125-140, 1976. 2019 APRIL

APRIL 2019 gearsolutions.com

[ 5 ] S. Jost, H. Langer, D. Pietsch and P. Uhlig, “ ‘Rechnerische Ermittlung der DECEMBER 2018 gearsolutions.com Erwärmdauer bei der Wärmebehandlung von Stahl’,” Fertigungstechnik und Betreib, vol. 26, no. 5, pp. 298-301, 1976.

August 2019 35 ISSUE POWDER METAL GEARS / CHAMFERING & DEBURRING FOCUS

DESIGN FEATURES OF WORM GEARING COMPOSED OF PLASTIC AND/OR POWDER-METAL COMPONENTS

36 gearsolutions.com The technology used in production of plastic gears, as well as powder-metal technology, imposes certain constraints on the design parameters of a worm and of a mating gear.

By STEPHEN P. RADZEVICH

his article deals with worm gearings in cases when the worm-gear pair is composed either of plastic or of powder-metal made components. T The technology used in production of plastic gears, as well as powder-metal technology, imposes certain constraints on the design parameters of a worm and of a mating gear. Gears of this kind are better suited for manufacturing, and, thus, they can be cheaper in production, while gears of other kinds are inconvenient in production, which makes them costlier. Certain advantages of gearing theory accom- Figure 1: An orthogonal “worm-to-helical gear” gear pair. plishments can be taken in order to combine the benefits of plastic-gear technology, and of powder-metal technology, with benefits of particular designs of worm-gear pairs. INTRODUCTION In recent decades, plastic gears, as well as powder-metal gears (PM gears) got an extensive application in a variety of industries. In many cases, gears of regular design can be successfully replaced either by plastic gears, or by PM gears that are usually less expensive and of a Figure 2: Nowadays, design of an orthogonal “worm-to-spur” gear pair: thickness of the worm top land, t , is much smaller higher quality. Unfortunately, not every kind of gears o.w compared to the space width, w , in the bottom land (t << can be made of plastic or use conventional methods f.w o.w wf.w). adopted in powder-metal industry. For example, spur gears are easier in production compared to worm gears, helical gears, double-helical and/or herring-bone a spur involute gear are known. An example of such gears, gears with circular arc geometry in the length- a gear pair is depicted in Figure 2. Here, a “worm-to- wise direction of the gear tooth, and so forth. spur gear” gear pair with a right shaft angle is shown In “worm-to-spur gear” mesh, it is a common and (S = 90°). It is right point to stress here that origi - well-established practice to set the worm in relation nally shown in the Figure 2 worm was designed to be to a mating spur gear at an angle that corresponds to engaged in mesh with a helical gear. Later on, width the worm pitch helix angle, yw. The shaft angle, S, in of the space between the worm threads was enlarged, this case equals S = 90° – yw. Such a case is illustrated and in this way, an additional room was created in in Figure 1. It is evident that the shaft angle in this order to get the worm engaged in mesh with a spur particular application is not a right angle (S ≠ 90°). gear. This is made clear from a comparison of the However, in particular applications, it is preferred thickness of the worm top land, to.w, and of the space to have worm gearings (a) with a shaft angle equal to a width, wf.w, in the bottom land. The first is much right angle, and (b) with a spur (not helical) gear in mesh smaller than the second (that is, an inequality to.w << with a mating worm. Under such a scenario, the spur wf.w is observed). There is no need to explain here that gear is manufactured using a technology adopted easier the obtained mesh is far from perfect, as the contact in production of plastic gears or PM gears. Manufactured conditions between the spur gear tooth flank, G, and this way, the gears get cheaper. The replacement of a the worm threads, W, are violated. In this particular helical gear with an equivalent spur gear is beneficial case, the helical gear pitch helix angle, “yw”, can be as the axial thrust pointed along the spur gear axis of interpreted as the axes misalignment deviation, “DS” rotation in this case is eliminated, and the shaft can be in the “worm-to-spur gear” mesh. All perfect gears mounted on bearings of a cheaper design. (with no exclusion, have to meet the three fundamen- It should be mentioned here that right-angle gear tal laws of gearing [1]). pairs with an involute worm engaged in mesh with Ultimately, it can be concluded from the earlier dis-

August 2019 37 cussion that the two requirements, that is, (a) to keep the shaft angle equal to a right angle, and (b) to use a spur gear instead of helical Orthogonal worm gear pairs may be gear, are contradictory to one another. designed so as to engage a spur gear The developments in the theory of gearing [1] make designing worm gear pairs with a right shaft angle S( = 90°) possible, and with in mesh with a mating involute worm a spur gear engaged in mesh with the worm. under a right shaft angle in the worm ELEMENTS OF THE THEORY OF ENVELOPING SURFACES When a worm and a mating spur gear rotate in mesh, a virtual gear pair. straight-sided rack is engaged in mesh with each of the components. This rack is commonly referred to as the “basic rack,R .” Tooth f lanks of the spur gear may be viewed as envelopes to the consecutive position of a tooth flank of the basic rack, R, in its motion in relation to a reference system associated with the spur gear. Generated this way, the worm is referred to as the “involute worm” (that differs from “Archimedean worm,” as well as from “convolute worm”). The same is also valid with respect to the mating worm: The worm threads may be construed as envelopes to the consecutive position of a tooth flank of that same basic rack, R, in its motion in relation to a reference system associated with the worm. With that said, one can conclude that the geometry of the tooth flank of the spur gear, as well as the threads of the worm, are generated as envelopes to a plane surface that performs a screw motion along and about a straight line, which, in nature, is the axis of rotation of the spur gear (of the worm). Following [1], the generation of an enveloping surface to consecutive positions of a plane that performs a screw motion is briefly outlined: In a more general case, that is, in a case of an involute helical gear, the generating basic rack, R, of a helical gear is tilted at a certain angle, yb.g, in relation to the axis of rotation of the gear as shown in Figure 3. When the gears rotate, the basic rack, R, travels in the direction specified by the vector, Vr. The magnitude, Vr, of the vector, Vr, of the linear velocity is synchronized with a rotation, wg, of the gear in a timely manner. The gear tooth flank, G, is an envelope to consecutive positions Figure 3: Generation of the tooth flank, G, of an involute helical gear by means of a helical basic rack, . of the lateral plane when the rack, R, performs the screw motion R along and about the axis, Og. To derive the geometry of a gear tooth flank, G, and of mating worm threads, W, consider a plane, R, that performs a screw motion, shown in Figure 4. The plane, R, forms a certain angle yb.w with X0– axis of the “Cartesian” coordinate system, X0Y0Z0 (shown later in this article, angle yb.w in nature is the base helix angle of a helical gear). The axis, X0, is the axis of the screw motion. The screw motion of the plane, R, is composed of two elementary motions: (1) The rotation with an angular velocity, mg, about the X0– axis. (2) The translation, Vr, along the X0– axis is another motion. The magnitudes, wg and Vr, of the rotation vector, mg, and the linear velocity vector, Vr, respectively, are synchronized with one another in Equation 1: Equation 1

Here, the pitch diameter of the gear is denoted by d . g Figure 4: Generation of a screw involute surface, G, as an envelope to consecutive The linear velocity vector, V , can be expressed as the sum of two r positions of a lateral plane of the rack, R, performing a screw motion. vectors in Equation 2: Equation 2 (V2 = Vrsinyb.g) and direction of this component. Based on the schematic shown in Figure 4, the following expres- The component V1 of the translation vector, Vr, is within the plane, sion in Equation 3: R. This component does not affect the geometry of the enveloping Equation 3 surface, G, and, thus, the component V1 can be omitted from further analysis. The component V2 is perpendicular to the plane, R. The was derived [1]. In this expression the worm base helix angle, yb.w, geometry of the gear tooth flank strongly depends on the magnitude is expressed in terms of the normal profile angle, fn, of the basic 38 gearsolutions.com correlates with involute gears’ tooth flank geometries generated using other method. A well-known schematic (available from the public domain) is used here intentionally (Figure 5). This schematic is adopted by many gear experts, which makes it easier to demonstrate the configuration of the rolling plane in relation to the involute gear tooth flank. The schematic is overlapped by the plane that performs a screw motion. It is instructive to stress that the plane, R, shown in Figure 4 is that same newly introduced plane in Figure 5. The earlier discussion on generation of a screw involute surface can be summarized with the following statement: If we screw, with pitch, p, a plane about an axis fixed in space, Figure 5: Instantaneous configuration of a plane that performs a screw motion, in which axis makes an angle, a, with the said plane, we describe in relation to a plane tangent to the base cylinder of the worm. Adapted from: https:// space a continuum of planes that successively intersect one another www.sdp-si.com/resources/elements-of-metric-geartechnology/page3.php in a continuum of straight lines. These lines sweep out the involute helicoid, (a, a), where a = ptana. rack, R, and of the angle, xr, that the basic rack, R, forms with the It might be correspondingly said that the screw of the plane perpendicular to the gear axis of rotation (see Figure 4). “sweeps” in the same involute helicoid. The involute helicoid is, in The expression in Equation 3 can be transformed and represented any event, the so-called “envelope” of the continuum of planes. in the form of Equation 4: This is a well-known theorem not found in most books about gearing. It may however be found in some books about kinematics Equation 4 [9]. See also page 335 in the book by Dr. Phillips [10]. Another solution to the problem of determining the envelope of a known from many advanced sources [3], and others. plane that performs a screw motion is given by Cormac [8]. It is important to stress that the angle (which is commonly referred to as the “worm setting angle, xr ”), and the worm pitch ‘SPUR GEAR-TO-WORM’ ORTHOGONAL GEARING helix angle, yb.g, are not identical to one another as they are of a At hand, the problem designing the worm can be formulated as fol- different nature. lows: To design an involute worm that can be engaged in a proper Equation 3 is the core for understanding “spur gear-to-worm” right-angle mesh with a spur involute gear. right-angle gearing. For an involute worm of a specified module, m, the number of The involute gear tooth flank, G, generated this way perfectly starts, Zw, normal profile angle, fn, and the worm-setting angle, xw, a sneak peek

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GMTA AD5302 GS Show Issue 2019 August 2019 39 stronger, and — what is also of critical impor- tance for highly-rotating worms — provide significantly better heat removal from the friction zone between the worm threads and the gear tooth flanks. The discussed approach for the calculation of the design parameters of an involute worm for a right-angle mesh with an involute spur gear also was used in designing hobs for cutting spur and helical cluster gears [5], [6], [7], and others. CONCLUSION Orthogonal worm gear pairs may be designed so as to engage a spur gear in mesh with a mating involute worm under a right shaft angle in the worm gear pair. The same is also valid with respect to two-starts worm gear pairs. Axial thrust in the spur gear is Figure 6: An orthogonal “spur gear-to-worm” pair. eliminated under such a scenario. The involute worm gear may be mounted on cheaper in Equation 5 (see Figure 6): bearings. No increase in design and production of a worm of such a design can be anticipated. Equation 5 The designed involute worm can be approximated either by a corresponding Archimedean worm or by a corresponding convolute is used for the calculation of the base diameter of the worm, db.w. worm (that is, by a worm, straight generating lines of which are not Once the shaft angle in a “spur gear-to-worm” pair is a right angle, tangent to the base cylinder, as no base cylinder can be constructed then the “worm setting angle, xr” has to be equal to zero, and, thus, to a convolute worm). an equation xr = 0° has to be valid. Under such a scenario, the equality Multiple-start worms can be designed using the disclosed yb.w = fn (see Equation 3) is observed. approach. In this particular case (that is, when xr = 0°) Equation 5 reduces to: The discussed approach is validated for designing hobs for hobbing spur and helical cluster gears. Equation 6

Having the base helix angle, yb.w, of the worm calculated, the rest REFERENCES of the design parameters of the worm are calculated as follows [1], [4]: [ 1 ] Radzevich, S.P., Theory of Gearing: Kinematics, Geometry, and Synthesis, 1. Axial pitch of the worm, px: 2nd edition, revised and expanded, Boca Raton, FL, 2018, 934 pages. Equation 7 [ 2 ] Radzevich, S. P., Design and Investigation of Skiving Hobs for Finishing of Hardened Gears, Ph.D. thesis, Kiev Polytechnic Institute, Kiev, 1982, 298p. Here, the module of the worm is designated as “m.” 2. Base diameter of the worm, d : [ 3 ] Radzevich, A.P., A Study on Efficient Hobbing of Cylindrical Involute Gears, b.w Ph.D. Thesis, Kuybishev, Kuybishev Polytechnic Institute, 1988, 300p. Equation 8 [ 4 ] Radzevich, S.P., Dudley’s Handbook of Practical Gear Design and Manufacture, 3rd Edition, CRC Press, Boca Raton, FL, 2016, 629 pages.

With the axial pitch, px, the base diameter, db.w, and the design [ 5 ] Radzevich, S.P., Gear Cutting Tools: Science and Engineering, 2nd Edition, parameters of the basic rack, R, known, the rest of the design param- CRC Press, Boca Raton, FL, 2017, 606 pages. eters of the worm can be calculated using known formulae [1], [4]. [ 6 ] Radzevich, S.P., “About Hob Idle Distance in Gear Hobbing Operation,” Having calculated the design parameters of a helical rack, the ASME Journal of Mechanical Design, Vol. 124, December 2002, pp.772- corresponding design parameters of a helical gear with a given tooth 786. number, N , can be calculated as well. Standard equations [1], [4], are g [ 7 ] Radzevich, S.P., “On a Possible Way of Size and Weight Reduction of a Car used for the calculation of the design parameters of a helical gear. Transmission,” Gear Technology magazine, July/August, 2003, pp. 44-50. Compare the design parameters of the worm of the proposed design (see Figure 6) with that shown in Figure 2. The performed [ 8 ] Cormac, P., A Treatise on Screws and Worm Gear, Their Mills and Hobs, London, Chapman & Hall, Ltd., 1936, 138p. comparison reveals that, for a spur gear with a standard tooth profile, tooth thickness and space width in the worm of the proposed [ 9 ] Prudhomme, R., and Lemasson, G., Cinématique, École Nationale Supérienre d’Arts et Métiers, École d’Engenieurs, Donod, Paris, 1906, design are equal to one another (ww = tw, measured on the pitch 1955. cylinders), while in the current worm design they are not (wf.w > to.w, measured on the bottom-land and outer cylinders correspond- [ 10 ] Phillips, J., General Spatial Involute Gearing, Springer, New York, 2003, ingly). The thicker threads in the worm depicted in Figure 6 are 498 pages.

ABOUT THE AUTHOR Stephen P. Radzevich, M.S., Ph.D., Dr. (Eng.) Sci., can be reached at 586-292-7209 or [email protected].

40 gearsolutions.com GET CONNECTED GearSolutions.com is your trusted online source for information and technical knowledge about the gear manufacturing industry, getting more than 42,000 page views each month.

Get your FREE subscription, plus our online content, at www.gearsolutions.com August 2019 41 TAKING DEBURRING TO THE NEXT LEVEL

The TM 200-R3 CNC produces finished work pieces in under a minute. (Courtesy: Helios Gear Products)

42 gearsolutions.com Recent developments from Helios Gear Products increase the productivity of the company’s Tecnomacchine CNC gear deburring technology.

By Gear Solutions staff

nce a gear is created, deburring becomes a diameters up to 200 mm (7.9 inches), but alternative necessary step to ensure a gear’s accuracy. configurations allow for parts up to 300 mm (11.8 Traditionally, deburring has been done by inches) and larger diameters. O hand, but that method can often take hours to complete. USER-FRIENDLY PROGRAMMING But with CNC technology, deburring can be done For the TM 200-R3’s processes, a TexComputer control faster and with much tighter tolerances than could panel is integrated directly into the machine enclo- ever be accomplished manually. sure and offers user-friendly dialog programming. CNC machines are becoming a common fixture Users can store programs on a memory stick or USB in both small job shops as well as large gear depart- drive to be saved for later use. This helps reduce set-up ments for major companies. Their speed and accuracy time. The TM 200-R3 also is equipped with an RJ45 often can make the initial cost a worthy investment. port for cost-effective remote assistance with Helios Gear Products or Tecnomacchine service personnel. CNC UPGRADE The TM 200-R3 CNC deburring machine has five Helios Gear Products (formerly Koepfer America) has workstations: made great strides in the field of gear deburring by Loading/unloading station. upgrading its Tecnomacchine model TM 200-R3. Deburring top station. Helios Gear Products, LLC specializes in the paral- Deburring bottom station. lel axis gear industry and offers hobbing machines Brushing top station. with optional automatic loading systems, worm and Brushing bottom station. thread milling machines, gear-inspection equip - ment, deburring and chamfering machines, consumable tools (including hobs, gear grinding, and Workers involved with setup honing wheels), hob and shaper cutter sharpening machines, and expert services for hob sharpening can easily adjust all tools and part inspection. for position, orientation, The TM 200-R3 CNC produces finished work pieces in under a minute. This productivity comes from the pressure, and speed up machine’s CNC workstations and flexible automatic loading and unloading system, and it offers gear to 30,000 rpm. Each of manufacturers a long-term competitive deburring solution. The TM 200-R3 CNC provides an optimum these CNC settings is balance between productivity and flexibility, which programmable and can is perfect for job shops as well as gear manufacturing departments with a complex variety of parts. be saved within the part COMPLETE DEBURRING, BRUSHING program. STATIONS This recent design iteration of the TM 200-R3 offers These stations can be equipped with milling tools, complete CNC deburring and brushing stations with cutoff wheels, and brushes depending on the opera- the ability to save all parameters within each part tion, and all stations work simultaneously for highly program. Each of the machine’s four stations use productive deburring; moreover, each station can be CNC for vertical, tangential, radial, and inclination individually turned off, allowing the option of hav- positions. ing only one station running. Like previous TM 200 models, this automated Workers involved with setup can easily adjust all solution alleviates human error and increases gear tools for position, orientation, pressure, and speed up deburring productivity by removing the need for to 30,000 rpm. Each of these CNC settings is program- repeated setups. This machine is ideal for job shops mable and can be saved within the part program. The and other gear manufacturing facilities for the stations are programmed via the control panel and machine’s ability to process diverse part types and are equipped with electric high-frequency tools or a sizes. The machine’s base configuration allows part silicon-coated nylon brush for the brushing stations.

August 2019 43 The TM 200-R3 CNC provides an optimum balance between productivity and flexibility, which is perfect for job shops as well as gear manufacturing departments with a complex variety of part. (Courtesy: Helios Gear Products)

The TM 200-R3 also includes CNC radial tool wear compensation ers occurs while the machine is brushing or deburring other parts. and uses flexible workholding solutions to accommodate a variety This process has the added benefit of saving even more operation of part sizes and types. time, which in turn, increases productivity. The TM 200-R3 CNC machine’s SPC (statistical process control) 10 CARRIAGE TOWERS station offers another advantage. This allows the operator to con- The loading table of the 2019 TM 200-R3 CNC has up to 10 total duct quality control on a part without stopping the machine’s part- carriage towers that rotate past the loading/unloading station. to-part cycling. The SPC station also allows operators to manually The operator can load all but one of the carriage towers with raw load/unload single workpieces safely and efficiently. parts to be deburred, and a pneumatic loader arm picks and places parts into the work area. The machine’s rotary table then transfers workpieces between stations allowing each part to be deburred and brushed before returning to the loading/unloading station. The heliosgearproducts.com placement and removal of the parts to and from the carriage tow- MORE INFO

44 gearsolutions.com ®

Modular Drawer System

August 2019 45 COMPANY ATLANTA GEAR WORKS PROFILE

‘ANY MAKE, ANY MODEL, ANYTIME, ANYWHERE’

Atlanta Gear Works is committed to doing whatever it takes. Any make. Any model. Anywhere. Anytime. (Courtesy: Atlanta Gear Works)

46 gearsolutions.com Atlanta Gear Works designs, engineers, builds, rebuilds, and repairs heavy industrial gearboxes for some of America’s leading manufacturers with one main goal — to minimize or prevent downtime.

By KENNETH CARTER, Gear Solutions editor

tlanta Gear Works set out in the beginning to training for everyone. do one thing and do it well: gearbox repair. “We do whatever it takes to keep our customers up But when the quality of the available com- and running,” he said. “We’re continually investing A ponents needed for their repairs wasn’t up to to add services so that we can bring the manufactur- the company’s standards, Atlanta Gear Works decided ing in-house, where we have control over it and can to expand. maintain the quality level.” “Originally, we just wanted to do gearbox repairs,” said Jack Conway, president of Atlanta Gear Works. TACKLING CHALLENGES “We didn’t intend to actually manufacture anything. It’s a process that Atlanta Gear Works takes seriously, But we kept finding it harder and harder to find quali- especially when a customer approaches the company fied gear suppliers that would deliver exactly what we with a challenge. wanted when we needed it. So, we wound up doing “We usually get the problem-child gearbox — the some machining, and then we added gearing and gear one that they’ve had continuous failures on,” Massa grinding. Today, we continue to add services to better said. “Our process is there’s no charge for us to go serve our customers.” through a gearbox. If a customer sends it to us, we That desire for the best quality continues to drive completely disassemble, inspect it, and develop a thor- Atlanta Gear Works. ough inspection report and a failure analysis where we can pinpoint the problem. Then we do a detailed CUSTOM PIECES engineering review of the system or the process. We “We repair process-critical gearboxes for large indus- present the scope of what we find, any upgrades or trial companies,” Conway said. “We service custom- modifications that we would recommend to improve ers that have a requirement for very high quality, and the reliability of the gearbox — or the gear if it’s just these are the customers that we can serve best. We also the gear that we’re manufacturing. Then, from there, manufacture gearing. Even there, in gearing, we look we execute what we quoted.” for customers that demand very high quality in gears.” That process involves making recommendations Those gears are typically low-volume, custom- to the customer about what caused the failure, along designed pieces, according to Conway. with any recommended upgrades to make the gearbox “We can make a gear from a sample or a custom- more reliable, according to Massa. But it doesn’t stop er-supplied print or design it from scratch to solve a there. Atlanta Gear Works will find out the complete particular problem,” he said. “We have a very skilled history of the gearbox, which includes past failure engineering department that enables us to reverse modes. After that, the company develops a detailed engineer every part we touch, basically.” engineering drawing of all the components. The staff In addition to gear manufacturing and gearbox engineers will then vet it before the needed parts are repair, Atlanta Gear Works also does field services produced. and field machining, which means in-place gear- “One of the things that sets us apart from other gear box rebuilds, replacement, inspections, and in-place companies is we can work on any gearbox — any make, machining, according to Craig Massa, vice president any model, anytime, anywhere,” Conway said. “We’ll of sales for Atlanta Gear Works. do it here, or we’ll do it at your plant. We’ll do what it “We solve our customers’ problems,” he said. “It takes to get our customer back up and running.” doesn’t matter what that problem is. In gearboxes, it’s about delivering a high-quality product that’s been THOROUGH INSPECTIONS engineered and assembled correctly every time. We With gearboxes in need of repair coming from a vari- document all of our processes; we measure everything ety of sources, Massa said Atlanta Gear Works makes that we do. We do that so we can deliver a product to sure the equipment gets a thorough inspection. a customer that’s reliable, and they know it’s going to “One thing that we tell our technicians is that we work when they put it in.” don’t know who’s rebuilt the gearbox before,” he said. Atlanta Gear Works achieves this by investing in “It may have been an OEM, or it could’ve been another its people, plant, and processes, according to Conway, repair shop. But we certainly don’t want to repeat any- investing in state-of-the-art equipment and ongoing one’s mistakes. That’s why we go over it with a fine-

August 2019 47 At AGW, full service includes a staff of experienced engineers capable of reverse-engineering any make or model to equal or better quality than original. (Courtesy: Atlanta Gear Works) tooth comb and do the detailed engineering review. Anything that around the clock here at our facility to manufacture the parts they doesn’t look right probably isn’t right.” need to get back up and running.” Not only can Atlanta Gear Works get any job done, but it also has That includes having field-service trucks that are fully staffed the ability to react quickly to a customer’s needs, especially if it’s and stocked with equipment that can react at a moment’s notice, an emergency situation, according to Carol Niemi, PR/marketing according to Conway. consultant for Atlanta Gear Works. “Most times, service calls are planned, but it’s not unusual to get “When they send a field services team out to a customer’s site, a call on a Friday night about 6 o’clock that a plant’s down or needs every one of them brings a packed backpack and is prepared to stay something quickly,” Massa said. there till the job is done — even for days on end,” she said. “They can But Massa said even planned service calls can sometimes morph turn a job around a lot faster because they have that kind of team into much more. in the field.” “We had one not too long ago with a big steel company where our guys walked in with planned scope of work to replace some high- FLEXIBILITY IS KEY speed pinion bearings,” he said. “The job was supposed to be just That unknown quantity when dealing with a customer’s problem is one day, but after our crew started the job, we found several more what makes Atlanta Gear Works’ f lexibility so important, according problems that needed to be addressed. The job ended up lasting to Conway. seven days, around the clock, including manufacturing new gears “We don’t know what we’re going to find when somebody’s in the and repairing several shafts. The parts came back here to be reverse middle of a breakdown,” he said. “When our crews go out to a cus- engineered and remade, and we sent our field machining crew to tomer’s plant, we’ll do the initial evaluation to help diagnose the re-machine the housing in place.” situation, consult with the plant, and give them our assessment of But even with the expanded work time, Massa said the mill didn’t what we think should happen. Once we agree on a plan, we might lose any downtime, and Atlanta Gear Works prevented an even big- bring in additional crews to work around the clock there as well as ger problem from striking in the future.

48 gearsolutions.com Visit us at Booth 4500

DEMO

G&E Model 120GH CNC Gear Gasher • 150” Diameter – can extend to 8M Diameter • NEW CONDITION

AGW field services crew removes a failed aerator gearbox from a water treatment plant — an example of AGW’s 24/7 field services support. (Courtesy: Atlanta Gear Works)

ADVANCING WITH THE INDUSTRY As the gear industry has advanced, Atlanta Gear Works has strived to advance along with it, according to Conway. “We’ve added gear grinding to our product offering,” he said. “We just put in some CNC gear-cutting equipment. All of the investment ‘08 Reishauer RZ-150 Gear Grinder ’07 Samputensili S-750 Gear Hobber w/Hoffman Filtration has just allowed us to produce a better-quality part in a shorter amount of time. That’s what our customers want.” And Conway said he expects his company’s expertise to continue to be a needed commodity in the gear world. “We’ll always have a place as a repair and rebuild facility,” he said. “The manufacturing equipment we’re using today is much different than what it will be in the future. The innovation in new machinery is fascinating, but if you can’t engineer the gear, you’re still not going to be able to produce one that will meet the customers’ needs.” Obviously, Conway sees engineering as one of the keys to Atlanta Gear Works’ continued success. “Our engineering team is led by Chris Dale,” he said. “They do an amazing job because he insists that everyone on his team knows how ‘97 Liebherr LC-122 CNC Gear Hobber ‘05 Gleason Pfauter GP-150S Gear Shaper to perform repairs and manufacture parts. They also continue to go to classes, and we invest in training software, whether it’s an auto CAD program, a CAM program in the shop. or a design program for 820 Cochran Street Statesville, NC 28677 704.609.0766 • [email protected] gearing. We have to stay on top of what’s happening in the industry in order to be relevant and to continue to serve our customers.” www.pisellient.com

THE #1 SOURCE FOR YOUR USED MEMBER GEAR MACHINERY — AND MORE! MORE INFO atlantagear.com

August 2019 49 PRODUCT SHOWCASE NEW PRODUCTS, TRENDS, SERVICES & DEVELOPMENTS

motor. Quad set of 70mm angular contact bearings and a 60mm rear taper roller bearing provide superior thermal stability, significant radial and axial stiffness and high accuracy as well as 900 kgf tool retention for aggressive cutting applications.

MORE INFO www.hardinge.com Hainbuch Maxxos T211 with hexagonal pyramid shape can cut costs The Hainbuch Mandrel Maxxos is a power- fully strong mandrel with hexagonal pyramid shape instead of a round taper, designed with stringent manufacturing requirements and process reliability in mind. Hainbuch has acted in response to demand from specif- The Bridgeport® V1320 vertical machining center is a fully digital, high-quality machine tool, designed to ic areas that has been growing year by year. achieve maximum capacity and performance. (Courtesy: Hardinge) Users are requesting mandrels that deliver higher performance as well as process reli- Hardinge introduces the job shop, OEM, aerospace, automotive, ability. The result is called Maxxos. It exceeds energy, and other demanding markets. even the specified customer requirements new Bridgeport V1320 V1320 features include: and, more than this, offers all the advantag- milling solutions Dual Y-axis ballscrews for improved sur- es of a hexagonal clamping mechanism. The face quality and roundness accuracy, accel- segmented clamping bushing with hexagon Hardinge Inc., the leading international eration, reduced vibration, and increased inside shape fits perfectly onto the clamping provider of advanced metal-cutting tool tool life. pyramid and enables maximum cutting per- solutions and accessories, introduces Easy and intuitive to use with new formance. The lubrication, combined with the Bridgeport® V1320 vertical machin- touch screen control: Equipped with its tightness ensures a very constant producing center. As an addition to its Bridgeport a 15” Mitsubishi M80 Color LCD touch tion f low and as a result, achieves maximum V-series vertical milling center line, the screen, users can intuitively control the reliability. Customers who value process reli- new V1320 is the best overall working cube machine. Pinch to zoom in and out, scroll ability and maximum torque transmission in its class, offering a high-quality, rugged, through screens, move pop-up windows on will be impressed with the Maxxos T211. and powerful machine center developed for the screen, or drag with a single finger. The Thanks to the hexagonal pyramid tough machining applications that is well M80 also will come standard with two 32 clamp, maximum torque transmission can suited for high-speed and hard metal cutting Gb SD card slots for memory expansion, USB conditions. program running, high accuracy modes, and The V1320 is a state-of-the-art advanced super smooth surface software. performance CNC machining center at the Provides superior machine accuracy top of the Hardinge milling product line, and repeatability with dual ballscrews: The said Michael Marshall, Hardinge’s global V1320 comes complete with oversized high- milling product manager. “Our machine class 45mm double nut Ballscrews, fixed centers provide not only highly accurate and and pre-tensioned and large 45mm linear precision detailed parts in the aerospace and high-quality linear guideways supported by medical industries but also the robustness to six trucks on the X and Z axis., with dual 40 handle the demanding day to day operations mm ballscrews on Y axis. in the automotive industry.” Confident cutting with a powerful spin- The new machine is a fully digital, high- dle motors: The new V1320 has a Big Plus, 40 The mandrel with hexagonal geometry for quality machine tool, designed to achieve taper, 12,000-rpm Direct Drive spindle pow- added process reliability and maximum cutting maximum capacity and performance in ered by a dual-wound Mitsubishi spindle performance. (Courtesy: Hainbuch)

50 gearsolutions.com be achieved, up to 155 percent more trans- machining. These plugs are available in missible torque and up to 57 percent higher standard sizes to accommodate different bending stiffness compared to the classic hole openings, and come with an O-ring and Mando T211 mandrel. This makes it possible tapped hole for easy installation. to achieve higher process parameters and consequently improve the yield of finished MORE INFO www.jergensinc.com parts. Greater process reliability is facilitated by the spacious layout between the clamping bushing and the clamping pyramid. Even Ecoclean offers during the clamping process, this design pre- vents virtually any dirt getting onto the sur- solvent-based cleaning faces. This significantly cuts down the fre- Jergens new fixture plate machining kits and receiver at high pressure quency of maintenance times for cleaning bushing plugs reduce time in setup and cleanup for and lubrication. Overall, the mandrel has a the popular Ball Lock® mounting system. (Courtesy: Increasing demands on cleanliness, in terms clamping diameter range of 18 to 100 mm. Jergens) of freedom from both particulate and film- The clamping areas of each size are designed type contaminants, call for the use of adapt- to overlap. This has the advantage that users used with during production. ed cleaning solutions. These now include a can choose from up to three mandrel sizes Another convenient development is the new spray cleaning system for solvent-based depending on the clamping diameter. The company’s new simple-to-install plugs that cleaning machines by Ecoclean. With this larger the mandrel is, the greater its stability prevent chips and coolant from accumulat- process option, spray processes and injection and rigidity. Smaller mandrels may be able ing inside receiver bushings that are not in flood washing can be performed at adjust- to handle more of the customer’s smaller use (during certain operations). This saves able pressures between 10 and 16 bar via two workpieces. Users are free to choose the size time by eliminating the need to clean out spraying bars. The additional cleaning capa- they want, based on their own judgment and receiver bushings in between setups. The bility delivers markedly improved cleaning preferences. The aligned, segmented clamp- receiver plugs are blue anodized aluminum, results on geometrically complex parts and ing bushings have a minimum concentricity a durable construction for better resistance bulk-cleaned items. of 0.01 mm and can even be supplied in a to hot chips when compared to plastic plugs. Spray cleaning systems are already a high precision version. The flush mount design does not protrude feature on many solvent-based cleaning Key advantages: above subplate surface making it easy to machines. However, their spraying pressure I.D. clamping mandrel for clamping clean of and ensuring no interference in is commonly in the range of 2-3 bar. With diameters of 18 to 100 mm. Ideal for stringent manufacturing demands and process reliability. Nordex.com [email protected] [email protected] Unique rigidity due to spacious layout Phone: (800) 243-0986 of the clamping segments. High transmissible torque and holding or Call: (203) 775-4877 forces. Contamination resistant due to hexagonal pyramid shape. Concentricity < 0.01 mm also available in high precision version. Gears, Pulleys & Racks www.hainbuch.com MORE INFO Made to Print Parts New machining kits, bushing plugs for Jergens Assemblies mounting system Jergens Inc. announces fixture plate machining kits and new receiver bushing plugs for its popular line of Ball Lock® quick-change mounting systems. The machining kits con- sist of one fixture plate, four extra-long Ball Lock shanks and four spacers that provide clearance between the fixture plate and subplate below. This open space allows cutting tools to ‘break through’ the fixture plate Standard Components without damaging the subplate, making it possible to machine fixture plates while Design & Engineering mounted to the same subplates they will be

August 2019 51 PRODUCT SHOWCASE densely packed bulk items and geometri- oping a high-pressure spraying system for cally complex workpieces exhibiting under- solvent-based cleaning machines. This system cuts, threaded holes and blind holes – and, allows spraying processes and injection flood at times, parts obtained by additive manu - washing with hydrocarbons or modified alco- facturing – that pressure will not suffice to hols to be conducted at 10-16 bar pressure. achieve increased standards of cleanliness, For the high-pressure spray cleaning i.e., an effective removal of film-type and/ option, the cleaning machine — e.g., an or particulate contaminants. This is because EcoCcore model — is equipped with a high- downstream processes such as coating, adhe- pressure pump and additional spraying bars sive bonding, and heat-treatment require sig- in addition to any 2–3 bar spraying device nificantly cleaner surfaces today. Ecoclean that may already be fitted. One spraying bar GmbH has responded to this trend by devel- is mounted on the interior wall of the work

The new high-pressure spray cleaning option for solvent-based cleaning machines such as the EcoCcore allows spraying processes and injection flood washing to be performed at adjustable pressures of up to 16 bars. Markedly improved cleaning results are thus achieved with geometrically High Tech is our Business complex parts and bulk-cleaned items. (Courtesy: Ecoclean GmbH)

ALD is a leader in vacuum chamber. The second is placed centrally in process technology and Heat the work chamber to provide both interior treatment services. or exterior spraying, either simultaneously or in an alternating pattern. The spray pres- LEADERS IN THE sure is adjusted via the high-pressure pump, CONTROL OF DISTORTION which is controlled by variable-frequency ALD Thermal Treatment, Inc. drive. The number of nozzles and the prod- + Low Pressure Carburizing uct movement can be conveniently adapted + High pressure gas quenching to optimize the spraying process for a given + Gas Nitriding part size and geometry. Moreover, this + Ferritic Nitro-Carburizing sophisticated and easy-to-handle technology + Plasma Carburizing supports the use of various nozzles matched + Normalizing to the specific application in terms of size + Hardening and jet shape. The pressure, spray duration, + Annealing spraying mode (simultaneous or alternating) + Brazing and product movement can be defined in a + Cryogenic Treatments part-specific cleaning program and stored + Engineering services and in the machine controller. process development For the interior and exterior spraying step, + Prototype and trials Global Service Centers the parts — whether oriented or bulk — are positioned and secured in special carriers.  Limbach-Oberfrohna With oriented parts the cleaning medium Germany can thus be selectively directed at critical zones. Defined movements of the wash load  Port Huron, Michigan Enrique Lopez – Sales and Marketing carrier ensure that the spray jet will reach all Email: [email protected] USA areas. Throughout the process, contaminants Phone +1 (810) 357-0685  Ramos Arizpe, Coahuila become dislodged from the part surface by Mexico ALD Thermal Treatment, Inc. the spray jet’s mechanical energy. At the same 2656 24th Street time, the high fluid exchange rate causes www.aldtt.net Port Huron, MI 48060, USA dislodged foreign matter to be flushed away from these areas so that a markedly improved cleaning result is obtained. The high-pressure spray cleaning capability also offers advantages in cleaning densely packed bulk items. Due to the elevated pres- Visit us at Booth 3200 sure, an improved penetration of the pack- ALD is a subsidiary of AMG Advanced Metallurgical Group N.V. ing will be achieved. For cleaning processes requiring only external spraying and/or no high-pressure

52 gearsolutions.com application, the central spray bar can be can be completely removed from the arm out compromising usability,” said Stephan removed in a few simple steps. in just seconds to allow for easier handling Amann, business director for the Absolute when not in use. Thanks to its innovative Arm range. “What we wanted is to provide a MORE INFO www.ecoclean-group.net repeatable mounting system, it can then be scanner that allows any user to walk up and remounted just as quickly and with no need measure, without worrying about settings. for recalibration when scanning functional- We want the data quality to be excellent, High-productivity 3D ity is again required. The RS6 also boasts a regardless of how experienced the user is.” unique laser targeting grid designed to sim- The RS6 Laser Scanner is available to laser scanner comes to plify measurement alignment. order, with the first units shipping in August “This is an exciting launch because we’re 2019. Hexagon’s Absolute Arm taking the scanning performance of the Hexagon’s Manufacturing Intelligence divi- Absolute Arm 7-Axis to another level with- MORE INFO www.hexagonmi.com sion has launched the RS6 Laser Scanner, a cutting-edge 3D laser scanner for the new generation of Absolute Arm portable measur- ing arm systems that was launched in 2018. This new scanner offers extremely high- YOUR INDUSTRY NEWS SOURCE density point-cloud data collection at high speeds and high accuracy. The RS6 delivers unmatched productivity improvements over competing scanning solutions through the Thermal Processing magazine is a trusted source introduction of SHINE – an advanced set of algorithms that allows RS6 to measure at the for the heat treating industry, offering both highest quality and accuracy setting with no technical and educational information for gear reduction in laser scan line width or scanning frame rate. manufacturers since 2012. The RS6 Laser Scanner boasts a scan line that is 150 millimeters wide at mid-range, Each issue, Thermal Processing offers its readers the latest, most representing a greater than 30 percent valuable content available from companies, large and small, as well increase in surface area covered by each as critical thoughts on what this information means for the future scan movement compared to the previous of the heat treating industry. generation Absolute Arm laser scanner. The scanner also measures faster than its prede- Best of all, it’s free to you. All you need to do is subscribe. cessor, with a threefold increase in frame rate to 300 Hertz, meaning scanning can be performed three times faster with no loss of point-cloud detail. Technologies and Processes for the Advancement of Materials “Often, the problem with high-perfor- Technologies and Processes for the Advancement of Materials mance laser scanners is that their adver- tised acquisition speeds seem incredible, yet when you measure with them in the real world, provisos and conditions mean that ISSUE FOCUS /// /// BURNERS & COMBUSTION the performance isn’t actually that special,” / INSULATING MATERIALS ISSUE FOCUS / CRYOGENICS said Anthony Vianna, product manager for VACUUM HEATING HIGH-EFFICIENCY Absolute Arm systems. “With the RS6, we’re THE ADVANTAGES OF AN providing a scanner that doesn’t leave the ALL-METAL VACUUMGAS BURNERS user disappointed in this way. Our new FURNACE HOT ZONEMAKE GOOD ECONOMIC SENSE SHINE technology means that users can scan COMPANY PROFILE /// /// COMPANY PROFILE Paulo at full speed with the full laser width all of Super Systems Incorporated the time, on all parts.” The SHINE technology means that the SUBSCRIBE FOR FREE RS6 is both better and easier to use than

2019 other scanners. There’s no need to learn www.thermalprocessing.comJANUARY thermalprocessing.com many complex combinations of settings

FEBRUARY 2019 depending on accuracy and surface-type thermalprocessing.com requirements; with SHINE, the RS6 is per- manently ready to scan any material at full accuracy with no reduction in frame rate, scan line width or data quality. Just like the RS5 Laser Scanner, the RS6

August 2019 53 High Gear Tools High Gear Tools

MARKET GEAR HOBS & CUTTERS

PLACE · Custom gear racks in AMERICAN and METRIC standards, STRAIGHT and HELICAL, VARIOUS materials, FINE and COARSE pitch (254 D.P. – 0.5 D.P.; 0.10 Module – 50 Module); hard-cut (up to Contact Gear Solutions 60 Rc) and soft-cut (up to 40 Rc); 32” face width; Up to 82” lengths – longer at 800-366-2185 to lengths through resetting · Custom gears in AMERICAN and feature your business We offer a complete line of gear METRIC standards (3 D.P. – 72 D.P., 10” Diameter) cutting tools including hobs, · Precision Quality up to AGMA 12 in the Marketplace! milling cutters, shaper cutters, · Prototype & Production quantities · Breakdown Service Available shaving cutters, special shaped · Reverse Engineering CNC cutting tools, threading tools, · Unique Tooth Configurations · Heat Treating reamers, and drills. · Complete CNC Machining

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KORO for Quality Hob Sharpening Service WE’RE think  Quick Turnaround 2 Day Service CERTIFIABLE outside  Spur Shaper Cutter Sharpening the Our ISO 17025 A2LA Laboratory is available  HSS & Carbide Hob with center hole to certify or recertify your Master Gears and box and straight flutes Spline Gauges or Contract  Thin Film Coatings Inspection of your gears.  Length up to 7 inches Our rapid turnaround

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Advertise with us in print and online, and you can reach over 45,000 potential readers – many who are key decision makers at their companies.

To learn more, contact assistant publisher Chad Morrison at [email protected] or call 800.366.2185 ext. 202

54 gearsolutions.com ADVERTISER INDEX CONTENTS PAGE NO.

AGMA (American Gear Manufacturers Association)...... IBC

ALD Thermal Treatment Inc...... 52

American Precision Gear Co...... 10

Circle Gear & Machine Co Inc...... 16

Forest City Gear...... IFC

Gleason...... 2

GMTA (German Machine Tools of America)...... 39

High Gear Tools...... 54

Innovative Rack & Gear...... 54

KAPP Technologies...... 29

KISSsoft USA LLC...... 11

Koro Sharpening Service...... 54 YOUR INDUSTRY NEWS SOURCE

McInnes Rolled Rings...... 13 Gear Solutions magazine has been the most trusted source for information and technical knowledge in the Mitsubishi Heavy Industries America Inc...... BC gear manufacturing industry for more than 15 years.

New England Gear...... 7 Each issue, Gear Solutions offers its readers the latest, most valuable content available from companies, large and small, as well as critical thoughts on what this information means Nordex...... 51 for the future of the gear manufacturing industry.

Penta Gear Metrology...... 15, 54 Best of all, it’s free to you. All you need to do is subscribe.

GEAR SOLUTIONS MAGAZINE MAGAZINE SOLUTIONS GEAR Piselli Enterprises Inc...... 49

GEAR SOLUTIONS MAGAZINE

Your Resource for Machines, Services, and Tooling for the Gear Industry Proto Manufacturing...... 12 Your Resource for Machines, Services, and Tooling for the Gear Industry

Russell Holbrook & Henderson Inc...... 10 ISSUE FOCUS

ISSUE FOCUS

THE ROOT CAUSE FOR GEAR NOISE EXCITATION NOISE GEAR FOR CAUSE ROOT THE Bevel Gears | Plastic Gears Cutting Tools | Workholding INCREASING STATIC FRICTION WITH LASER THE ROOT CAUSE FOR STD Precision Gear & Instrument Inc...... 11 INCREASING GEAR NOISE STATIC FRICTION EXCITATION WITH LASER Stor-Loc...... 45, 54 COMPANY SUBSCRIBE FOR FREE PROFILE COMPANY PROFILE PISELLI ENTERPRISES www.gearsolutions.comWEILER ABRASIVES

The Broach Masters Inc...... 4 DECEMBER 2018 DECEMBER

APRIL 2019

APRIL 2019 gearsolutions.com Toolink Engineering Inc...... 1 DECEMBER 2018 gearsolutions.com

United Tool Supply...... 55

August 2019 55 T.J. BOUDREAU Q&A CATEGORY MANAGER  INTERVIEW WITH AN WEILER ABRASIVES GROUP INDUSTRY INSIDER

“This is a company with unique technology, and we are extremely customer focused.”

What’s a typical day like for you at Weiler? experience a cooler cutting grinding wheel that holds form better; I wished there was a typical day — no such thing really. Our team this will reduce our customers’ dressing consumable cost and again does a lot of collaborating. We have four or five people in the field on reduce overall cycle time. any given day, and they are calling on four or five different custom- There are a myriad of mechanical and thermodynamic advan- ers, so there always seems to be an interesting new challenge to tack- tages in being able to produce grinding wheels with very open le. A day does not go by where I don’t speak to one of our field team structures. We can pair our V59 bond technology with advanced members about a specific customer problem or interesting issue and aluminum oxide technologies and have an aluminum oxide wheel work with that team member to find the best solution for customer. that is far more capable of metal-removal rate and form holding — I also do a lot of coordinating with our factory in Europe. I try to something not previously available to the marketplace. help make sure that we are focusing on the right things and doing We also have developed a unique ceramic grain technology. When what we need to in order to be a market leader in terms of quality, we pair these grains with our new V59 bond, we’re able to produce the service, and delivery. highest performing wheels in the world and, in-turn, offer gear manufacturers significant improvements in their grinding applications. What is Weiler doing to provide its customers with increased engineering support? What does Weiler hope to gain from its recent AGMA We have a formal program called Weiler Process Solutions (WPS), membership? which focuses on working directly with end users and understand- We joined AGMA because it is an opportunity for us to learn. We ing how we can bring value to their unique applications. At a basic are committed to being the market leader in the gear grinding level, we examine what they are doing and work to understand their and deburring markets. So, for Weiler to be part of AGMA, that challenges. We document their entire process to make sure that we means we can learn from and partner with the most innovative are properly leveraging our technology and expertise to help solve gear companies in the world. their unique manufacturing challenges. The organization is known for being on the cutting edge. By understanding their full manufacturing processes, we can help They are the people who come up with the standards that set solve many different types of problems relating to quality, delivery, the tone for the industry, and being a member will allow us to and consumable spend. The WPS tools help us clearly define our network and collaborate with some of the best companies in customers’ manufacturing challenges and document the cost savings the world. and productivity gains our products help them achieve. We are a company with unique technology, and we are extreme- We have four application experts placed throughout the coun- ly customer focused. AGMA will give us a chance to collaborate and try, but no one has a specific geography per se. If a particular team stay out in front of the technology that is being developed, while member has an expertise that is suitable for a specific customer’s giving AGMA a partner in grinding and deburring. challenge, we will get them on an airplane to support that cus- Also, by joining the AGMA, we have the opportunity to be tomer. We make sure the appropriate technical team member is a part of AGMA’s technical committees. We intend for some of available to work with our customers and solve their manufactur- our team to join one of the technical committees and contribute ing challenges. their expertise. I think it is an excellent opportunity and an excellent fit for the Weiler Abrasives. What has Weiler been developing that will aid in gear manufacturing? What should attendees expect when they stop by your booth at The Global Weiler team has recently developed a new bond technol- the Motion + Power Technology Expo in October? ogy for gear grinding that we are calling the V59 bond. I like to think We will have our new V59 bond technology on display, and we will of the bond as the foundation of the grinding wheel as it represents be displaying our full gear-grinding offerings in terms of geometry, roughly half of the grinding wheel, and it is what holds everything shape, and size. We will also be introducing attendees to our deburr- together. Our new bond is extremely strong. This strength allows us ing technology, including our wire-brush technology and our Nylox to produce grinding wheels that are safer and stronger than other brush technology. vitrified bonds in the market. Weiler V59 bond gear grinding wheels Our booth will be staffed by our technical experts, so attendees will be rated for very high speeds, up to 80 meters per second and can have an immediate discussion about some of their technical chal- occasionally higher for specific applications. The increased strength lenges, and hopefully we can solve them right there on the floor. of our V59 bond also allows us to make very high porosity wheels. This porosity allows for greater chip clearance and penetration of coolant into the grind zone, which results in higher metal removal weilerabrasives.com rates as well as shorter cycle times. Additionally, customers will MORE INFO

56 gearsolutions.com MOVING THE FUTURE. OCTOBER 15–17, 2019 | COBO CENTER | DETROIT, MICHIGAN

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