Chamfering Process Chamfering Is Carried out Between Two Cuts During Hobbing

Gear S ol

u tions MAg azine

Go Big Go Indexable Cost Reduction Using Powder MetaLl

Gearin for Pump and Metering Gears g Up to A Better Chamferin Squeezing Productivity Out of Gear Milling g and D Operations e bu rrin g P ro c ess Gearing Up to A Better Chamfering Materials Matter andDeburring Tooth Tips HOT SEAT Process Gear Expo Wrap-up Company Profile: NAMCO Machine and Gear Works, Ltd.

O C Q&A: scott richards TO

B Vice President ER 2013 James Engineering

OCTOBER 2013 gearsolutions.com Indiana Technology & Manufacturing Companies, Inc. (ITAMCO), left to right: Joel D. Neidig - Technology Manager Gary Neidig - Vice President Nobel Neidig - President

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30 Features Gearing Up to a Better Chamfering and Deburring Process By Karl Schäferling The chamfering and deburring of gears is often an undervalued process in gear production. Company Profile: However, it has a great influence NAMCO Machine and on the usage characteristics of the Gear Works, Ltd. workpiece. By Tim Byrd This family-operated Edmonton gear 26 company’s rich history is evident in its work ethic and substantial product line.

Go Big, Go Indexable By Todd Miller Advanced carbide insert technology 40 meshes with increased demand for large gears.

Cost Reduction Using Powder Metal for Pump and Metering Gears By Bob Aleksivich and Ernie Wheeler The powder metal process provides engineered components in just about every industry today, especially 44 producing high quality gears of all types. Precision pump and metering gears from powder metal is one of many of these applications.

Squeezing Productivity Out of Gear Milling Operations By Aaron Habeck When we talk about the broad and 48 common operation of slot milling, the name of the game is chip thinning.

OCTOBER 2013 3 BroachmasterFP.indd 4 12/20/11 2:36:20 PM Resources MACHINERY Departments

53 Industry News MARKETPLACE Trends, data, and developments to keep you aware of what’s happening with your colleagues in the gear-manufacturing industry 62 around the country and world. 8 Materials Matter ADVERTISER Kyle Rackers INDEX To better understand why the center is in tension, one can do simple volumetric calculations of consecutive ring segments of a 21 round cross section. 63 Tooth Tips OCTOBER 2013 | VOLUME 11 / NO. 10 Stefanie Burns The all-steel hypoid gear technology is recognized for high efficiency, durability, and quiet operation. 22 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: Hot Seat $72.00 per year. Periodicals Postage Paid Jack Titus at Pelham AL and at additional mailing Nissan has announced that it will offer a driverless car in 2021. offices. Printed in the USA. POSTMASTER: There is no doubt others are working on similar technology. 28 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 Product Showcase Beaver Creek Richmond Hill, ON L4B4R6. News of products, equipment, and resources from across the

No part of this publication may be repro- duced or transmitted in any form or by any means, electronic or mechanical, including Q&A photocopy, recording, or any information Scott Richards, storage-and-retrieval system without per- Vice President mission in writing from the publisher. The 64 James Engineering 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 web site, which is assumed to be cleared for release. Comments and submis- 17 sions are welcome, and can be submitted to [email protected]. Post Gear Expo 2013 Wrap-Up This year’s Gear Expo was another success for the American Gear Manufacturers Association, and Gear Solutions was there to experience it all. For those who missed out (or just want to relive it), we’ve written this summary using testimonials, opinions, and some great photography.

Cover Photo: Gleason Corporation

OCTOBER 2013 5 Letter From THEEDITOR David C. Cooper Publisher

ORLANDO, September 20—The bustle has subsided now. The booths have all been packed up and Chad Morrison shipped. Front desk clerks are checking in new hotel guests. Exhibitors and attendees, having converged Associate Publisher this week in Indianapolis for the gear industry’s premier event, now journey home. As the Gear Solutions staff awaits the departure of our final flight home out of Gate 121 at Orlando International Airport, I can’t help but reflect back on the events of the past week. What was the “experi- EDITORIAL ence?” How can I wrap Gear Expo 2013 up in a nice, neat, little package for our readers? Stephen Sisk I can’t. Not here. Telling the whole story is impossible to put in so few words. An attempt at doing so Editor would be a disservice to the AGMA, to Gear Expo, and to you—our readers. Besides, I’d wager that this experience is unique to each individual. If I were to ask 100 people what Tim Byrd Gear Expo 2013 meant to them, odds are I’d get 100 different answers. Managing Editor To a manufacturer, it may have meant proudly showcasing its products and technologies. The engineer or designer may laud the Fall Technical Meeting for its free and open exchange of ideas and scholarship. Sales To the salesperson, Gear Expo was an opportunity to generate leads and identify customer needs. Chad Morrison The small, family-owned shop may have been looking for a way to keep its head above water. Associate Publisher The first-timer may simply have described the event in a single word: “overwhelming.” Gear Solutions will be telling these stories in the months and years to come. For now, however, we sit Michael Sellaroli wearily amid a three-hour layover. It’s not so much our time in Indy that has taken a toll on us, but the Regional Sales Manager months of preparation. Long hours at a computer or on the phone, technical difficulties, considerable financial expenditures, and dozens upon dozens of single-serve coffee portions have all gone into assuring our readers get the greatest benefit possible from our presence at Gear Expo. Circulation This week, we saw the fruit of all of our labor, and it wasn’t exhausting at all. It was invigorating. Here Teresa Cooper are some highlights of our Gear Expo 2013 experience: Manager • Gear Solutions’ September “Gear Expo Issue” was the largest single issue in our 11-year history Kassie Hughey • We took more staff to Indianapolis for Gear Expo than ever before. Coordinator • We wrote a two-part series outlining the AGMA’s (and Gear Expo’s) benefits and contributions to the gear manufacturing industry. Jamie Willett • We launched the Gear Solutions Mobile App—an all-in-one industry phonebook/calendar/network/ Assistant information solution—at Gear Expo 2013. • Coinciding with the App launch, we overhauled gearsolutions.com, making more information easily accessible with responsive design, improved usability, and other enhancements. ART Jeremy Allen We’ve been busy, but we’ve also set the bar high. While we are motivated to get home to our loved CREATIVE Director ones, we’re equally anxious to get back to work—developing a long-term vision for how to best serve our readers. The countdown to Detroit begins now. We know you hold us to the highest standards, and we’re committed to exceeding those expectations. Rebecca Allen Two months ago in this column, I commented on AGMA President Joe Franklin’s use of the term Graphic Designer “catalyst” to describe the both the association and Gear Expo. Now that the event has come to an end, this statement rings even more true. The agent of change has performed its duty. We are now all charged Michele Hall with carrying our experiences back to our shops and offices and getting down to business. Gear Solutions Graphic Designer would like to encourage you to follow our lead and strive for excellence in order to ensure continued prosperity for the industry. Contributing writers On a personal note, I’d like to personally thank everyone who stopped by our booth at Gear Expo, as Bob Aleksivich well as those who made time for us elsewhere at the show. We are proud to have strengthened existing Stefanie Burns relationships, while also seeing a lot of new faces. We learned a lot about how to best serve your needs, Aaron Habeck and we will continue to do so the best we know how. Todd Miller Kyle Rackers These types of relationships provide a firm foundation for this industry. Building these relationships is Karl Schäferling one of the AGMA’s chief concerns in hosting Gear Expo, and is vital to the health of the industry. Jack Titus To paraphrase a statement made often by our publisher: Success in business should never come at the EVerniertical WheelerLogo Horizontal Logo expense of anyone with whom you do business. While we each have our individual goals, we share one big goal in common—growth and prosperity for the gear manufacturing industry. It’s our belief at Gear Solutions that if we all strive to achieve the “big” goal, we will realize our individual goals along the way.

Published by Media Solutions, Inc. Coop wants to use this one for the website P. O. Box 1987 • Pelham, AL 35124 Stephen Sisk (800) 366-2185 • (205) 380-1580 fax editor David C. Cooper Gear Solutions magazine President [email protected] Chad Morrison (800) 366-2185 x209 Vice PresidenT

Teresa Cooper Operations

6 gearsolutions.com

INDUSTRY New Products, Trends, Services, NEWS and Developments

Gear Solutions Names Stor-Loc Toolbox Winners at Gear Expo 2013 Gear Solutions and Stor-Loc are pleased to announce that three Gear Expo 2013 attendees were the lucky winners of a heavy-duty toolbox. The toolboxes were given away as part of a daily drawing at Gear Solutions’ booth at the bi-annual event, held September 19–21 at the Indiana Convention Center in Indianapolis. The winners, pictured above from left to right, were Dana Clark of Autotech Driveline; Jerry Hendrickson of Willman Industries; and John Brennan of Mitsubishi Gear Machines. “Gear Solutions would like to congratulate Dana, Jerry, and John on being the lucky recipients of these toolboxes,” said editor Stephen Sisk. “Response to the drawings was overwhelming. We were scrambling each afternoon to get everyone registered.” Each day of the event, attendees were invited to sign up for a free subscription (or renew their current subscription) to Gear Solutions. Participants were then entitled to enter the toolbox drawing, held daily at 2 p.m. at the Gear Solutions booth. “Gear Expo 2013 was a successful event for Gear Solutions. In addition to strengthening existing long-term industry relationships, we saw a lot of new faces with whom we were able to share our vision for being the primary source of information for the gear manufacturing industry.” Coinciding with Gear Expo 2013, Gear Solutions recently launched its Mobile App—a one-of-a-kind gear industry networking and informational tool. The Mobile App is a free download for iOS devices, and can be found on the Apple App Store using the search word “gearsolutions.” Additionally, Gear Solutions has recently re-designed its companion website, gearsolutions.com. Enhancements include a responsive design that automatically adjusts to varying screen sizes, greater ease of use, and a greater volume of information at the user’s fingertips on the home page.

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

8 gearsolutions.com Jonathan Markley Appointed Oregon, and Washington. The key appoint- ership in the machine tool industry and will Managing Director of Seco/ ment of Garcia, a known machine tool indus- play a critical role in our west coast expansion Warwick Corporation try veteran of more than 20 years, buttresses plans moving forward.” Methods’ strategic plan for aggressive west Methods will open a technology center coast expansion. in the Northern California region, where “We’re very pleased to have Fernando join Garcia will be based. He will also be expand- Methods,” stated Bryon Deysher, president ing Methods’ sales, service, and applications and CEO of Methods Machine Tools, Inc. presence throughout the entire west coast “He brings a wealth of experience and lead- region. Beginning as a machinist, Garcia

Jonathan Markley has been appointed to the position of managing director of Seco/Warwick Corporation in Meadville, Penn. As managing director, Markley is responsible for Seco/ Warwick’s day-to-day operating activities, including revenue and sales growth, expense, cost and margin control, profitability, and monthly, quar- terly, and annual financial goal management. Most recently, Markley served as General Electric Transportation’s global sales director for the surface mining division, where he was the senior sales executive leading the integration and global sales expansion of Fairchild International. During his career at GE, he has held both global sales director and commercial operations leader positions in surface mining, as well as participating in the Edison Engineering Development program within the GE health- care division. An Erie, Penn. native, Markley holds a B.S. in computer engineering from Penn State University and M.S. in engineering management from the Milwaukee School of Engineering. For more information, visit www.secowar- wick.com.

Methods Machine Tools Appoints Fernando R. Garcia as General Manager, West Coast Operations Methods Machine Tools, Inc. has announced the appointment of Fernando R. Garcia as general manager, west coast operations, to head up all Methods operations in California,

OCTOBER 2013 9 has been fully involved in the manufacturing industry throughout his career. Prior to joining Methods, he was president of Ellison Technologies since 2009 and held various executive and sales positions, primarily with Ellison, for more than 20 years. Garcia has posted a consistent track record of growth in each of his endeavors and was a board of directors member of AMTDA/AMT. For more information, visit www.methodsmachine.com.

Mazak Certifies SIM Technologies as Newest VIP Partner Mazak Corporation has named SIM Technologies Corporation, an engineering services firm specializing in software development for the manufacturing and distribution industries, to its exclusive Value Inspired Partner (VIP) technology program. Through this partnership, SIM Technologies and Mazak will col- laborate on solutions that solve production, scheduling, logistics, and that embodies what it means to be a VIP,” said Brian Papke, president inventory challenges. The two companies will also work together to of Mazak Corporation. “Like Mazak, SIM Technologies is committed create training programs and seminars on understanding and solving to making its customers more productive and profitable by solving production bottlenecks for presentation at Mazak technology and their production challenges.” education events across the country, including the DISCOVER 2013 SIM Technologies offers software-based planning systems that event taking place Oct. 8–16 at Mazak Corporation headquarters in focus on global supply chains, capacity scheduling, flexible manu- Florence, Kent. facturing simulation, lean manufacturing, and congestion modeling. “We are excited to have SIM Technologies as our newest VIP Projects range from optimizing throughput of an existing produc- partner. Having relied on them to optimize our own manufacturing tion line to the complete global supply chain process for a company. initiatives, we know firsthand the company is a proactive collaborator Mazak relies on SIM Technologies to continuously improve the work-

CIRCLE GEAR and MACHINE STRAIGHT BEVEL GEARS .25” to 34 ½” Diameter 32 DP to 1.5 DP .5 Module to 16 Module

NEW RELEASE

Highlights 03/2013 SPIRAL BEVEL GEARS ● Improved contact analysis of cylindrical gear pairs and planetary systems .25” to 33” Diameter ● Sizing of plastic gears according to 32 DP to 2 DP VDI 2736 ● Automatic, easily customized, .5 Module to 12 Module generation of manufacturing drawings ● Fine sizing of worm wheels and Since 1951 Circle Gear has served crossed helical gears Chicago land as a full service gear manufacturing facility. In addition ● New DIN 743 and FKM in the shaft to bevel gears Circle Gear also calculation provides spur gears, helical gears, KISSsoft USA, LLC ● KISSsys assistant for planetary models herringbone gears, worm and gear 3719 N. Spring Grove Road sets, internal gears, splines, racks Johnsburg, Illinois 60051 and sprockets. Phone (815) 363 8823 Get your free trial version at [email protected] www.KISSsoft.com

10 gearsolutions.com V2_GearSol_KISSsoft_Rel_03_2013_96x124mm.indd 1 7/9/2013 2:44:00 PM flow of its Kentucky manufacturing plant via with a 53’ x 22’ x 14’ workspace powered Flexible Manufacturing Simulation System by 40,000,000 BTU’s with a 1,000,000- software upgrades. pound load capacity and operating tem- “It is an honor to receive Mazak VIP certi- peratures up to 2150º F. fication, because it further validates our com- The equipment and services now offered mitment to the manufacturing industry,” said here include: five car bottom furnaces; Paul Eckard, president of SIM Technologies five box furnaces; heavy-duty polymer and Corporation. “We are excited to be able to water quench tanks; stress relieving; sand take our working relationship with Mazak blasting; prime and finish painting; anneal- to the next level and serve as a key factor in helping their customers reduce capital and operating costs through our specialized solutions.” For more information, visit www.maza- kusa.com.

Complete Heat Treating Concludes Acquisition of Wisconsin Steel Assets Complete Heat Treating, LLC announced the completion of its acquisition of all assets and equipment of the former Wisconsin Steel Industries, Inc. Complete co-owners Jake and TJ Dolhun made the announce- ment from the company headquarters. The purchase of Wisconsin Steel was made by Complete in 2011, with the relocation of all equipment and key personnel having now concluded. All equipment from both companies has been consolidated at the 65,000-sq. ft. Complete facility in Milwaukee, where the highlight is a gas-fired car bottom furnace

OCTOBER 2013 11 ing; normalizing; BHN inspection; straighten- als-handling equipment, rail systems, construc- ing; saw cutting of test specimens; tractor/ tion equipment, power generation, oil & gas, trailer fleet; and full compliance with ISO 9001 and other machinery. certification standards. Workpieces to 50 tons For more information, visit www.completeht. are routinely processed here, using existing and com. new crane equipment recently installed. Customers for this commercial heat treater Seco Tools Announces Fall Event include many of the Midwest’s leading builders Schedule of farm equipment, mining equipment, materi- This fall Seco will spotlight its latest cutting tool solutions paired with applications expertise for all manufacturing industry segments, from aerospace to power generation, at several trade shows and industry events throughout North America. The event schedule is as follows:

• Oct. 8 – 16: DISCOVER 2013, Mazak North American Headquarters, Florence, Kent. • Oct. 22: Competitive Manufacturing Summit, Cleveland, Ohio • Oct. 22 – 24: Wichita Industrial Trade Show, Wichita, Kan. • Oct. 23 – 24: Advanced Manufacturing Technology Show, Dayton, Ohio

“Seco is excited to be associated with so many great events during the fall season,” said Lisa Seidl, Seco’s manager of marketing communications. “We especially enjoy having the opportunity to meet face-to-face with our customers and demonstrate the many ways in which we can help them increase their productivity and profitability in today’s challenging marketplace.” Over the next two months, Seco’s event schedule will take the company coast-to-coast in the United States, as well as to Canada. At each event, attendees will have the opportunity to learn about new Seco products and advances to its existing products, as well as how Seco is addressing the needs of an ever-changing marketplace. For more information, visit www.secotools.com.

Walter Wins Innovation Award at EMO 2013 Walter AG, parent company of Walter USA, together with machine tool manufacturer Starrag AG, has won the MM Award for Innovation for having the most innovative exhibit at EMO 2013 in the milling category with its production-scale machining of turbine

blades with CO2 based cryogenic cooling.

12 gearsolutions.com KISSsoft AG News the macro geometry is varied in desired Fine Sizing for Worm Wheels and areasand the optimal solution according to Crossed Helical Gears various criteria is selected from the calcu- For the calculation of worm wheels and lated variants. Plastic helical gears can be crossed helical gears, fine sizing modules directly calculated according to the new are now available (module ZD5 and ZE6). draft of the VDI 2736. The KISSsoft fine sizing is applied to After the cylindrical and bevel gears, gear optimizations of all kinds—from stat- these fine sizing modules complete the siz- ic strength to noise optimization. Thereby, ing process for all toothings. Walter Cryo·tec™ CO2 milling cutter—F2334R model for turbine blade machining. Walter AG and the Swiss manufacturer of machining centers Starrag first conducted a live demonstration of the jointly developed solution for cryogenic milling with CO2 cooling in spring 2013. The most prominent feature of the approach is the liquid supply of CO2 coolant through the machine, spindle, toolholder and tool, right to the cutting edge—all without loss of pressure at room temperature. Cooling to a maximum of minus 99° F first occurs at the nozzle, when the CO2, which has been in liquid form until that point, expands. Users are able to machine up to 70% faster in comparison to dry machining. Conversely, the cryogenic CO2 cooling doubles the tool life, as long as the cutting parameters are not increased. The developers at Walter and Starrag have refined their solution even further by developing a second media channel that supplements the CO2 cooling. This channel can be used for aerosol or minimum quantity lubrication (MQL) for milling high-strength alloys for extremely heat-resistant turbine blades. Because both media, CO2 and MQL, are completely separated and only come into contact with one another at the tool cutting edge, this allows for highly efficient lubricating. “We are delighted with the award but we are not going to stop there,” said Mirko Merlo, CEO of Walter AG, “because Walter and Starrag are already testing a three-channel solution, in which CO2, aerosol and even emulsion can be guided through the spindle.” In the future, Walter will provide tools with cryogenic process cooling under the brand name Cryo·tecTM. Machines from Starrag are already available with optional CO2 cooling. The MM Award, from MM MaschenenMarkt is open exclusively to exhibitors at EMO and must feature a commercially available machine, system, process or tool. For more information, visit www.walter- tools.com.

OCTOBER 2013 13 When Weeks ARE Just toO long ... Fine sizing software from KISSsoft Extended options for optimizing gear modifications ison, especially within different partial loads. WE SHIP In as fEW as 5 days Custom Configurable Manufacturing For more information on KISSsoft products By combining the latest in ring Drawings for all Cylindrical Gears and services, visit www.kisssoft.ch. rolling technology with experienced For all cylindrical gears, custom configurable manufacturing drawings are now available in Membership News people, McInnes delivers the best value in carbon, alloy and stainless KISSsoft (module ZPK). The toothing data Announced by CSIA steel rolled rings. and a range of different graphics—such as The Control System Integrators Association flank modifications—can now be displayed in (CSIA) announces the following companies one graphic, output to screen or paper, and recently joined the association or became sent to the toothing manufacturer. At the same recertified. time, graphic position and scale can be set by New integrator members include: • ARKK Engineering, Oak Park, Mich., U.S. • BTB Solutions LLC, Ridgefield, Wash., U.S. • Fosdick & Hilmer Inc., Cincinnati, Ohio, U.S. • Ingautin de Colombia Ltda, Bogota, Colombia • Innovative Engineering Systems Inc., Bakersfield, Cal., U.S. Manufacturing data for cylindrical gears • Intecol SA, Medellin, Antioquia • MBA Engineering, Ham Lake, Minn., U.S. the user on his own. Now toothing data can • Superior Control Systems Inc., Tempe, be easily arranged and placed on the graphic. Ariz., U.S. The settings are saved in a separate file and • The jdi group, Maumee, Ohio, U.S. thereby adopted for all gears. This approach • QDS Systems, Baton Rouge, La., U.S., favorsalso the definition of company standards. recently became recertified.

Evaluation of Gear Modifications in the To become a CSIA Certified member, a Radar Chart member company must pass an independent Another highlight in the KISSsoft release is audit with stringent performance standards in Carbon · alloy the extended settings and evaluation options nine management categories: general; human for optimizing modifications of cylindrical and resources; marketing, business development stainless steel planet gears. and sales; financial; project; system develop- A new feature is that the face load factor ment lifecycle; supporting activities; quality Rings · 4˝- 144˝ OD KHβ can now also be calculated. This there- assurance; and service and support. fore reveals the direct influence of the tooth Certified members are re-audited every trace modification on the safeties of the classic three years and recertified if they meet cur- www.McInnesRolledRings.com tooth root and flank load capacities. rent performance standards. The certification 1.800.569.1420 Modifications are evaluated in the radar criteria is spelled out in CSIA’s Best Practices chart, which also provides a very clear compar- and Benchmarks, a roadmap for system inte-

14 gearsolutions.com grators committed to delivering the level of modified endmills, but rather makes use of REGO PLUS. Licensed by BIG Daishowa, quality, performance, and long-term support existing standard carbide or HSS endmill REGO PLUS products are compatible with their customers expect. designs. The standard ground notches found all BIG PLUS spindles. Founded in 1994, the Control System on most Weldon-type endmills readily accept SOUTH-TEC attendees working with Integrators Association (CSIA) is a not-for- secuRgrip’s locking key insert for fast, easy high-precision applications will want to profit, global professional association that seeks assembly. The secuRgrip system is appli- check out the PG6 toolholder, which has a to advance the industry of control system cable for use with REGO-FIX PG 25 or run-out accuracy of less than three microns integration. Control system integrators use PG 32 holders in all tapers, including CAT, and easily accesses tight, difficult-to-reach their engineering, technical, and business skills BT, TC, HSK, CAPTO and dual contact features in small complex parts. As the to help manufacturers and others automate their industrial equipment and systems. CSIA members provide a range of services in dozens of industries. For more information, visit www.con- trolsys.org.

REGO-FIX to Showcase Advanced Tooling at SOUTH-TEC 2013 Toolholding innovation will take center stage in the REGO-FIX booth 330 at SOUTH- TEC 2013, scheduled for Oct. 29 – 31 in Greenville, S.C. The company will present its new low-cost retrofit solution for the internal cooling of driven tools as well as showcase advanced tooling systems that bring precision, strength, and ease of use to demanding part machining applications. Show attendees seeking an affordable, low- maintenance solution for extending the tool life of their milling cutters and drills must check out REGO-FIX’s new reCool cooling system. reCool allows manufacturers to retrofit their driven tools to be able to benefit from internal or peripheral cooling, which is much more effective in getting coolant to the cutting edge when compared to spray pipes or nozzles. The advanced tooling systems SOUTH- TEC attendees will see inside the REGO-FIX booth include the powRgrip toolholding collet system as well as the secuRgrip anti-pull system and slim-nose PG6 toolholder, which are both new options for powRgrip. For added confidence when machining expensive, tough materials in high material- removal applications, REGO-FIX will demonstrate its secuRgrip anti-pullout system that locks in collets and cutters. This specially designed toolholder eliminates cutter slippage by providing tremendous gripping strength in conjunction with a patented locking key system and threaded cap. secuRgrip does not require the purchase of expensive specially

OCTOBER 2013 15 smallest toolholder in the powRgrip product series, PG6 has a minimal outside diameter of 0.4” and a clamping diameter from 0.008” to 0.125”. As a result, it provides less tool interference, machines tight pockets and delivers high levels of productivity. SOUTH-TEC attendees will experience REGO-FIX’s new milling chucks designed to provide the least possible amount of run-out and highest possible gripping force available from a milling chuck. Ideal for roughing and finishing, the milling chucks provide concen- tricity of 0.0004” at 4 x diameter and can be reduced with sleeves for versatility to match the tool with the specific machining application at hand. Helical internal slots and extra thick walls help ensure durability, long working lives, and smooth clamping. Furthermore, the multi- seal design of the chucks helps keep dirt and debris out and seals the system for coolant through applications. Milling chuck nuts seat positively against holder body bases to reduce the risk of over tightening and increase holder rigidity and stability. The roller bearing cages of the holders incorporate alternating patterns that distribute clamping forces evenly around cutting tools to ensure the best possible T.I.R. and system repeatability from clamp to clamp. Milling chucks work in CAT 40, CAT 50, BT-40 and HSK 63A spindles in sizes ranging from 0.75” to 1.25”, while milling chuck sleeves accommodate tool diameters from 0.250” to 1.00”. REGO-FIX will present reCool, a retrofit solution for the internal cooling of driven tools at SOUTH-TEC 2013. For more information, visit www.rego-fix.com.

A COMMON SENSE APPROACH IN CNC Continuous THE MANUFACTURING OF WORLD Generating Gear CLASS GEARS Raycar manufactures high Grinding Machines quality smooth running gears Built for long standing performance offering competitive pricing and quick turn around. Burri BZ331 & BZ362 Each machine is built on • CNC GEAR BLANKING the mechanical basis of • CNC GEAR SHAPING Reishauer RZ301/RZ362. After a Burri retrofit the • CNC GEAR HOBBING machine is technically • CNC GEAR GRINDING comparable to the latest machine generation. Burri • ANALYTICAL CHARTING machines are rebuilt to EQUIPMENT be modern and innovative technology, competitive with today’s expectations for reduced set-up time and lower costs of gear grinding.

www.machinetoolbuilders.com 815.636.7502 WE WANT THE OPPORTUNITY TO MAKE YOUR NEXT HIGH QUALITY GEAR SEND YOUR QUOTES TO:

Raycar Gear & Machine Co. Phone: 815.874.3948 6125 11th Street www.raycargear.com Call MTB: 815.636.7502 or visit www.machinetoolbuilders.com Rockford, IL 61109 [email protected]

16 gearsolutions.com We’ve had lots of great comments about the show. Our booth was busy from Tuesday afternoon on through the last day of the show. We’ve had some great activity and some real prospects for terrific leads.

—Wendy Young, Forest City Gear As far as Gear Expo is concerned, you HAVE to be here. If you’re not here, people start wondering: “Why aren’t they here?”

—Kevin Tagney, Arrow Gear Company

Gear manufacturers, suppliers, and significant gain (10 percent) over the 2011 over 1 million pounds of freight on the show service providers convened at the Indiana event, which was held in Cincinnati, Ohio. floor.” Convention Center in Indianapolis on “I’ve been really happy with attendance,” This year, as always, participants took September 17-19 for the industry’s premier said Jenny Blackford, marketing and advantage of the opportunity to meet and conference and exhibition—Gear Expo communications director for the AGMA. network with industry peers, learn about new 2013. “It’s a much bigger show this time around products and technologies, and view tool and The biennial, three-day event, hosted in terms of square footage, number of machinery demonstrations. by the American Gear Manufacturers exhibitors, attendance, and also in terms Company-sponsored presentations were Association, event drew 3,416 attendees of the number of machines on the floor. hosted daily at the Gear Expo Solutions and 227 exhibitors. Attendance showed a We had 750,000 pounds of machinery and Center booth. Daily keynote presentations SERVICES

18 gearsolutions.com Attendance is up this year; we’ve noticed that specifically in the first and second days of the show. We’ve also already re-enlisted for Gear Expo 2015 in Detroit. Gear Expo is always a well-attended, focused show. We will continue to exhibit.

—Dennis Richmond, Reishauer AG

covered additive manufacturing, the Chinese products,” said Blackford. “So it’s a ready-made gear drive components, and materials/heat manufacturing economy, and the U.S. gear audience for them.” ASM is already planning treatment. A show hightlight was 3M’s Walter manufacturing market outlook. to co-exhibit with AGMA Gear Expo 2015 in Graf discussion of how precision-shaped grains Newly added for Gear Expo 2013 was a Detroit. are turning the concept of gear grinding “upside smartphone app for iPhone and Android devices, The Fall Technical Meeting that preceded down.” allowing attendees to view and customize event Gear Expo 2013 was packed with attendees Listening to the conversations at the reception schedules, search exhibitor listings, and view and information. For three days, the industry’s following Sunday’s remarkable first session, the exhibition floor plan. The app also featured leading technical experts presented the results where some of the greatest mechanical minds general conference information, a photo gallery, of their studies in the most advanced realms of in the world interacted over drinks and hors Twitter integration, and a note taking function. today’s gear technologies—gear manufacturing, d’oeuvres, was a dream-come-true for gear In 2015, Gear Expo will be held in Detroit gear design, failure analysis and inspection, enthusiasts young and old. at the Cobo Center. The facility is currently in the third phase of a massive five-year, $299 million renovation. Project completion is scheduled for January 2015—in plenty of time to host Gear Expo 2015. Major enhancements include: the addition of 25,000 square-feet of exhibition space; a 30,000-square-foot atrium; a 40,000-square-foot ballroom (a redevelopment of the Cobo Arena); utilities upgrades; and the redevelopment and modernization of offices, OVER parking facilities, and parking facilities. 50 Years The AGMA expects the upward trend of Serving Industry Gear Expo attendance and exhibition to carry over to the 2015 event in Detroit. “We always expect growth,” Blackford said. “We’re positioned to make (Gear Expo 2015) larger than this year.” As such, the association is already booking exhibition space for the 2015 event. Interested companies are urged to email exhibition inquiries to [email protected]. Also in the exhibit hall was the ASM Heat Treating Society’s 27th Conference and Exhibition, co-located with Gear Expo 2013. The show featured over 100 companies associated with heat treat displaying their services for the most heat-treated industry of all—the gear industry. “Gear manufacturers are the largest buyers of heat treating services and

OCTOBER 2013 19 We had quality visits from interested parties on a regular basis. I expect good things to come of it.

—John Ketterer, Engineered Tools Corporation

GEARING AHEAD TO MEET INDUSTRY'S DEMAND FOR PRECISION --Serving-- Aircraft • Aerospace • Actuation Instrumentation • Optic Robotics • Radar • Medical Marine • Defense • Experimental Prototype • Production Hi-Performance Automotive

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20 gearsolutions.com consider that each ring segment has the same volumetric expansion. Next, take the mid-wall circumference and multiply that by the volumetric MATERIALS expansion resulting from quenching. While maintaining a constant before and after wall thickness, calculate the MATTER new OD and ID dimensions (Table 1). The new OD and ID should mismatch from each kyle RACKERS ring segment to the next. Figure 1 depicts that the largest Scot Forge ring segment has the largest circumferential growth for the same percentage of growth of the next layer. The To better understand why the center is in tension, one outermost ring segment is pulling away from the next can do simple volumetric calculations of theoretical integral ring segment (Figure 1). This accumulates from consecutive ring segments within a round cross section. layer to layer putting the center further into a tensile stress. Now consider chemical segregation and changes in Computer simulations also help to illustrate the setup of residual stresses after quenching microstructure throughout the thickness. Progressing (Figure 3). towards the center, carbon content increases; therefore for A simulation was performed for AISI/SAE 4140 steel, 1016 mm (40 in.) in diameter, and the same transformation product there will be a smaller heat transfer coefficient (htc) of 800 W/m2K. The largest observed tensile stresses correlated increase in volume. Also, due to the size and differences in with the fracture origins typically observed. The von Mises stress from the simulation was 800 cooling rates, it is probable that different transformation MPa (116 ksi). It is difficult to obtain the as-quenched strength of the center of a 1016 mm products of lower volumetric expansion will form closer bar due to safety concerns of sectioning such a sample. It is conceivable though that 4140 steel to the center (Figure 2). with cooling rates seen at the center of a 1016 mm polymer quenched bar would have a UTS This increases the mismatch between each ring and YLD close to 800 MPa. segment putting the center in a higher tensile stress state To minimize some of the thermal stresses a simulation was performed to find the optimum (Table 2). time to remove the bar from the quenchant. Removal would occur just before the center of the bar is predicted to transform. It would then be moved to a furnace operating at a temperature range just below the nose of the bainite start curve. This would give an optimum temperature to begin snap tempering the surface while the transformed material continues to extract heat from the center, thereby equalizing the thermal gradient and stress. As the surface tempers, stresses are relaxed due to carbide segregation and a resultant volumetric contraction occurs. Our software currently does not account for this microstructure Figure 1: Theoretical ring segments before (left) and after change or contraction but it is in the plans for future modeling software versions. Also the center (right) quenching. is now transforming at a higher temperature further reducing thermal stresses.

Conclusions Cracking is occurring due to accumulative stresses between transformation products and thermal stresses. When parts cracked while quenching, their surfaces were coated with quenchant, which turned blue during tempering. Fractures not coated in quenchant formed a common grey to reddish tempering scale. All fractures were of a brittle nature. Even though transformational stresses are inherent in the process, the likelihood of quench cracks can be reduced by alleviating thermal stresses and tempering transformed products. Figure 2: Volumetric expansion from austenite to transformation product. OD mid wall ID % Growth new OD mid wall2 new ID mismatch 30 25 20 4 31 26 21 0.4 20 15 10 4 20.6 15.6 10.6 0.4 10 5 0 4 10.2 5.2 0 Table 1: Dimensions of theoretical ring segments before/after quenching with 4% growth in each segment.

OD mid wall ID % Growth new OD mid wall2 new ID mismatch 30 25 20 3.8 30.95 25.95 20.95 0.41 20 15 10 3.6 20.54 15.54 10.54 0.365 10 5 0 3.5 10.175 5.175 0 Figure 3: Computer simulation output of residual stress Table 2: Dimensions of theoretical ring segments before/after quenching considering effects of lower distribution and stress tensors (vector of first principle stress). volumetric expansion. About the author: Kyle Rackers is a metallurgist for Scot Forge. He can be reached at (815) 675-4347. For more information about Scot Forge, visit www.scotforge.com

OCTOBER 2013 21 Durability The more durable your gearbox, the lower your maintenance TOOTHTIPS and replacement costs. Over a period of several years, a company will also realize total cost of ownership benefits by stefanieBURNS switching to a gearbox that may initially be more expensive, Sumitomo Drive Technologies but has zero maintenance cost (due to its durability) and possibly the option of maintenance-free grease lubrication, available with hypoid gearboxes. The all-steel hypoid gear technology is Lubrication recognized for high efficiency, durability, and Oil churning, seal drag, and friction account for most of the quiet operation. efficiency losses in gearboxes. To some extent these three sources are all affected by lubrication. Seals ride on a thin oil lubricant film. Churning losses are due to the gearbox In comparison, worm gear drives use softer, bronze gearing, which shortens service components moving through the oil sump. life, and they operate at efficiencies that decline as ratio increases. Hypoid-gearing efficiency In order to increase gearbox efficiency, by changing only stays relatively flat and begins to show significant efficiency advantages for ratios greater lubrication, you must use the thinnest oil that provides than 30:1 ratio. For these reasons, companies choosing hypoid gearing technology for their adequate film thickness and contains a good Anti-Wear or application usually see significant utility cost savings, and a resultant reduction in their Extreme Pressure additive package that provides protection carbon foot print. when transient conditions do not provide an adequate To calculate the annual utility cost, use the following formula: oil film. Synthetic oils and oils that have an exceptionally low traction coefficient will reduce internal friction losses. Cost = Rate x Connected Horsepower x 0.746 x Hours Run In addition, efficiency increases result in lower operating Motor Efficiency x Gearbox Efficiency temperatures. The rule of thumb is, for every 20 degrees F decrease in temperature lubricant life doubles. According to the US Energy Information Administration (EIA), the United States generated 1,006 billion kWh of electricity in 2007. It is generally accepted that electrical motors account for about seventy percent of industrial electrical power consumption. Assuming that electric motors are all driving gearboxes, every one percent increase in gearbox efficiency saves the equivalent yearly output of an 800 MW power plant. Small changes in efficiency can Table 1: Total utility cost: commercial rate have a large aggregate impact. Unlike other efficiency- improving ideas, lubrication changes require no changes to existing equipment.

It’s Safe For applications such as elevators and hoists, engineers will typically choose a hypoid gear design over worm gear for safety reasons. Since hypoid has more gear contact, it offers more durability than a bevel design. Also, because it uses Table 2: Total utility cost: industrial rate all-steel gearing, unlike the worm gear that uses a softer bronze gearing, the gear will not wear over time. When you have an instance where a gear wears down over time, a gear tooth can fail at any moment, leading to catastrophic failure. In the case of an all-steel hypoid design, the gear tooth will wear more slowly—and in the worst-case scenario you will receive warning indications that a gearbox is about to fail with rumbling and grinding noises. Backlash is always going to increase for worm gearboxes due to the wear in bronze gearing. In addition, special lubrication must be used for worm gears. There are certain lubricants with additives that Table 3: Operational costs/total savings will attack yellow gears and make them weak.

22 gearsolutions.com This is not to say that worm gears do not have advantages. Worm manufacturing brand they will use for their application. If a gearbox gear configurations in which the gear cannot drive the worm are said to is unnecessarily oversized—specifically, if the power capacity of the be self-locking. For higher ratios, worm gears are self-locking—meaning, gearbox greatly exceeds the power of the applied motor combined with even Arnold Schwarzenegger could not grab the output shaft and make the application service factor, much of the motor power will be used to it move backwards. It is a safety feature that acts as a brake. But when it overcome the constant losses within the gearbox thereby leaving little comes to people movers, be cautious of using worm gears that offer few additional usable power/torque for the application itself. In short, this warning indications of gearbox failure. would be a situation where the speed reducer is yielding a very low efficiency. Conversely however, a gearbox undersized for an application Conclusion runs the risk of low life expectancy due to overload conditions despite a While the greatest efficiency loss is typically associated with the interaction seemingly high efficiency. of the gears in mesh, other factors and components also influence the There are many factors that affect efficiency. Due to the durability overall efficiency of a system. A gearbox manufacturer is expected to create and longevity of the hypoid gear design, it is often possible to replace gearbox designs that minimize efficiency losses within the product through a worm gearbox/motor combination with a smaller horsepower input variety of means. Utilizing high quality gearing with superior surface finish hypoid and actually receive greater torque at the driven shaft. In addition, on the gear teeth combined with the incorporation of low-friction seals and hypoid gearboxes offer the option of grease lubrication that can eliminate bearings all serve to maximize the power efficiency of enclosed gearing oil leakage. By eliminating oil leaks, your operation will be cleaner and product lines. maintenance free. Engineers looking to make their operations greener are To the user, the most important factor in selecting a gearbox is looking into grease lubricated gearbox designs for this reason. Deworm your whether or not that gearbox size is optimized for their application. Size operation and replace it with hypoid gearboxes for efficiency improvements and weight restrictions may dictate what type of shaft arrangements or in your overall system.

About the author: Stefanie Burns is the international marketing manager of Sumitomo Drive Technologies. She has industrial marketing background of over 10 years, and is a graduate of Virginia Tech.

OCTOBER 2013 23 However, chains eventually stretch as well. Remember Honda’s early rubber timing belts that required changing HOTSEAT at 150,000 miles to avoid valves smashing into the tops of pistons? jackTitus At this time, I don’t believe any (drivetrain) belts AFC-Holcroft currently in use, if in fact there are in use, are made from rubber compounds, steel-reinforced or not. One of the first below the radar successful chain-drive transmission applications was used in the 1966 Olds Toronado. Nissan has announced that it will offer a Originally patented by Ford years earlier, it never saw driverless car in 2021. There is no doubt others the light of day. Ford conceived a chain directly driving the transmission input shaft from the engine output or are working on similar technology. Contributing crankshaft. For Olds, this novel FWD system allowed the to the effort, the European Union is debating “V” engine to be positioned longitudinally, as in RWD cars, with a special high strength; heat treated and pre- implementing speed limit signs that signal cars stretched chain connecting the side-saddle rear-pointing transmission to the engine crank shaft. This engine/ to brake if they detect an offender. Similar ideas transmission combination was used for many years and are being discussed in the U.S. even drove GMC’s 1973–'78 Motorhome. Will the CRS survive in its current form when the belt Driverless technology, in its fundamental form, already exists in is designed to accommodate the horsepower in today’s academia and private consortiums. The basic components are here: GPS can track and automobile engines survive? That is the challenge, sense a car’s position anywhere, along with its location, speed, direction, and altitude. considering all of the past unsuccessful attempts to OnStar can turn the car’s engine off and control most computer-controlled functions. replace gears in an automobile transmission, driverless Sensors such as infrared and radar can detect the car’s position on the highway and its or not. distance from other cars. There’s almost nothing left to the imagination—technology It’s not easy to duplicate the load and direction- exists to control practically everything. However, the applicable artificial intelligence changing ability that hardened gears offer to thousands required to approach human decision making in real world traffic is still a ways off. of applications (for which the automobile transmission Driverless automobile technology is probably just one of the hundreds of R&D and differential are the most advanced—they’re used by projects on the drawing boards and in development around the world and most, if not more people around the world than any other system). all, are targeting the “green revolution” as the justification. One in particular is called And there’s a good reason why: Transferring energy Controlled Rotation System [CRS], a bicycle transmission morphed to replace the from the motor to the wheels creates large compressive gearbox in cars. CRS has been patented by Parts Services Holland, Ltd.—formed in and tensile stresses within the gear teeth, in addition to 2009 by four people in Holland to replace the Derailleur bicycle chain-jumping sprockets whisper-quiet precision. Chains and belts, on the other by using a belt and only two discs whose diameters can be hydraulically changed to alter hand, can be surprisingly noisy, especially at high RPM. their ratio. Unlike the CVT, continuously variable transmission, where the belt rides up With my limited knowledge of the material detail and down cones to vary the ratio, the CRS’s belt is in constant contact with each disc of the CRS device, I see three possible options: as the diameters change. In theory, according to the inventors, the motor could run at a Heat-treated steel chain, composite reinforced linked constant RPM and the car’s speed and torque would be increased or decreased by just chain, or a space-age rubber or polymer reinforced changing the disc’s diameters. Obviously a clutch or torque converter of some design belt. Most likely hardened steel micro-linked chain, would still be required to accommodate engine/motor disengagement from the CRS. modified to ride on the toothless expanding discs, Beyond tripping over this device via an internet search, I know nothing more about it will be required. If gears were used, the continuously other than the principles expect it to force a sea-change in how future automobiles will expanding and contracting disc diameter would cause be designed. In addition, the company sees application for wind turbines among other the gear module to change, altering the pitch. In any power transmission devices. Their goal is to improve operating efficiency by eliminating case, the hydraulically expanded discs will see very gears thereby per their claims reduce friction losses. high wear, thus require a heat-treated surface (a perfect There’s a big “but”: The auto industry has a long history with belts, and anyone with application for nitriding, actually). experience with belts know that they stretch—requiring a tensioning idler of some sort. The RPM required for a bicycle is one thing—the Belts for direct drive applications were eventually dropped, and chains took their place. wear and load-carrying ability required for a 200- to 400-horsepower automobile is quite another. Even with About the author: the comparatively low loads endured by racing bicycles for which I assume the CRS was developed, the current Jack Titus can be reached at (248) 668-4040 or [email protected]. bicycle chain-drive systems are changed frequently. Note Go online to www.afc-holcroft.com or www.ald-holcroft.com. in the Tour de France the multitude of bicycles every team uses to compete over just a few days.

24 gearsolutions.com

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COMPANY PROFILE NAMCO Machine and Gear Works, Ltd. This family-operated Edmonton gear company’s rich history is evident in its work ethic and substantial product line.

By Tim Byrd

26 gearsolutions.com

Bernard Vukovic’s parents, Ivan and Kate Vukovic, emigrated from Croatia and lived in Germany for 5 ½ years, where his father learned the machinist trade. While in Germany, his parents were committed to finding a place where they could secure employment and, more importantly, citizenship. When the opportunity to move to Canada presented itself, they embarked on a journey to better their lives and seek out opportunity.

After working for a couple of local machine shops, the proper opportunity presented itself in February of 1976. In the early years, NAMCO Machine and Gear Works, Ltd. was a small shop with an adherence to a strong work ethic, a commitment to high quality, and a knack for expansion, the Bcompany grew from making a few custom gearboxes to its current status as a gearbox leader. By vertically integrating gear cutting in-house, NAMCO’S quality and capabilities have expanded steadily over time. “NAMCO is located in Edmonton, so we are well-situated for the mining and forestry industries,” said Vukovic. “In Alberta, the dominant industry is oil & gas. Because of our full range of capabilities, we are able to design any type of custom gearbox our customers can imagine. “We built our first gearboxes in 1978 and 1979, mostly for split-shaft or power takeoff applications, and a few transfer cases for heavy, oil-filled applications. At that time, the gearboxes were simple—a few pieces of welded plate along with a few rough-cut gears, all created on milling Services/Baker-Hughes, Badger Daylighting, etc. NAMCO machines with a single-tooth cutter. Over time, we bought produces approximately 1000 units per year. Their main a few hobbing machines, and in 2000 we bought our first manufacturing shop is 33,000 sq. ft. with an assembly bay gear grinder.” of about 5000 sq. ft. and a welding bay of about 7000 sq. When Bernard joined NAMCO, he moved the company ft. Originally functioning from a 15,000 sq. ft. building into a more product-based form. Ivan was an excellent across the street (now a small machine shop used for small tradesman who grew up with a special kind of hands-on gearbox casing and welding), their current facilities span experience that involved him in every job. But Bernard approximately 60,000 sq. ft. didn’t have a machinist background. “I had an engineering “Our range of equipment is significant,” Vukovic said. background,” he said, “so it was more difficult for me to run “We have lathes and milling machines (all CNC high- the company as a job shop.” quality equipment), a Pfauter 1200/1600 gear hobber, a The father and son team sat down and developed a plan Pfauter 1200/1600 gear shaper with an extended stroke, that incorporated both skill sets, as well as those of their a Gleason 400 hobber, a Pfauter 600/800 grinder; and managers and staff. This cooperation and compromise has the Pfauter 800/1200 gear grinder was our first machine, turned NAMCO into a producer that has created its own bought back in 2000. As far as machine tools go, NAMCO product lines. It took some time, but NAMCO eventually sources from the best suppliers/manufacturers in Europe, moved from a job shop to a service company model and North America, and Japan.” eventually towards the product-based company it is today. Only about 5% of the work is still job shop. “15 years These evolutions leveraged their growth substantially. ago,” he said, “that was predominately what we did. Today, Vukovic said, “We’ve developed a patented design for we sell a lot of custom gearboxes. We have built gear drives our gearbox cases using hollow structural steel. It’s a very up to 20,000HP, but our ‘sweet spot’ is from 400 to 3000HP. rigid design and very lightweight, much more cost-effective We have built gearboxes for radar stations, some with 120:1 than casting a gearbox with split-halves. We designed the reduction ratio that fit in the palm of your hand. We are case so that everything can be assembled from the outside extremely versatile, with a wide range of capabilities.” as one solid structure. This product has been a welcome All of the design and engineering is done in-house, by addition to the market. Customers appreciate the ease and one of the leading gear engineers in North America, Nikica effectiveness of the design.” “Nick” Markovic. After immigrating to Canada from This particular line of products serves quite a few Croatia, Markovic was introduced to Ivan Vukovic by an industries. They are installed in Peterbilt, Western Star, acquaintance. “The rest is NAMCO history,” Bernard said. Kenworth—all the major truck manufacturers in North “We’re glad to have such a brilliant engineer on the team, America. They are used by fleets such as Halliburton, BJ leading the design elements of the company. In designing a

OCTOBER 2013 27 Europe, he began by working the drill press and as a mechanic on the floor; with his engineering degree, he later became a foreman and worked his way up. Now the VP of the company, Bernard describes him as a ground-up, hands-on type of guy. “It’s what sets him apart from other engineers. He knows the practical workings of machinery, as well as the theoretical. This two-pronged approach allows him to know what is possible and what might be possible.” Bernard knows NAMCO’s success doesn’t hinge on one person. “Our entire staff is exceptional,” he said. “Davorin (Dave) Dikic, our production manager, has been a big part of our success as well. He has walked the shop floor thousands of times over and keeps over 60 tradesmen and hundreds of jobs in line and organized. Dave and Nick have been instrumental in the development of our products and ingenuity. I am proud to work with such an exceptional team of people.” But Bernard saves his highest praise for his father, Ivan. “His vision, sacrifice, and determination, along with the gearbox application, we talk to the customers and see exactly what contribution, support, and tireless efforts of my mother Kate, is needed (torque, horsepower, and envelope). We have an idea built a company that is a stand alone in our industry in terms of about how they work, but without talking to the customer directly, quality, community, and innovation. I am proud and honored to it is more difficult to know exactly what is required. We’re experts have worked with my father, and am even more proud to be his in gearing, they’re experts in their respective fields. Nick will son. We have had a great run and built something that will never then design the gear train and equipment, and he’ll put together be replicated.” a proposal for the customer to review.” Markovic’s technical knowledge and education, coupled with For more information: his extensive hands-on experience, have made him an invaluable Visit www.namco.ca or call 780-463-5602. asset to the NAMCO organization. When he came over from

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28 gearsolutions.com YOUR SINGLE SOLUTION FOR MULTI-TASKING

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The chamfering and deburring of gears is often an undervalued process in gear production. However, it has a great influence on the usage characteristics of the work piece.

By Karl Schäferling As with any machining process, the manufacturing of gears by hobbing or shaping results in burrs on the front edge. These burrs must be removed because they are hazardous to machines, tools, operators, or the process in general. This chamfer and deburring process should be carefully considered at the beginning of a new project for gear manufacturing.

Unfortunately this isn’t always the case. Instead, the focus in many cases is mainly on hobbing or shaping, but it should be kept in mind that almost every gear needs to be chamfered and deburred (Figure 1). AFor instance, the hardened burrs can break off inside the gearbox and lead to failure of the gears and bearings. Residual burrs in the tooth gap after hardening are extremely sharp and will quickly destroy the grinding or honing tools during hard- fine finishing. The operators handling the work pieces run the risk of injuries caused by sharp and pointed edges of the burrs. The chamfering itself has two main tasks. A chamfered tooth is protected against damages during the handling of the work piece. This means the risk of nicks in the active flank is minimized. The other task of chamfering is to avoid the risk of over- carburizing the pointed front edge of the tooth during case hardening. This results in breakage under load. For all these reasons, gears must be chamfered and deburred. The chamfering and deburring process is often technically undervalued and does not receive the attention it deserves. However, ignoring the issue can lead to inevitable production downtimes. The Processes The most important processes used in the industry are briefly described Fig. 1: Workpiece before and after chamfering and deburring. below: Manual chamfering and is moved axially to the point of processes generally work with one or deburring with hand tools: This processing with a plunge cutting feed, more swinging grinding/milling tools is a difficult and quite imprecise stays there for an instant, and is then that use adjustable contact pressure process primarily used for low-volume retracted to the starting position. to probe the edges of the teeth. The or large gears. Grinding with disk-shaped chamfering quality depends on Impact milling: In impact grinding wheels and/or milling these forces and the rotational speed milling, the rotating milling tool with rotary cutters: These selected for the work piece.

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2710 West Caro Rd., Caro, MI 48723 1307 E. Maple Rd., Suite “G”, Troy, MI 48083 PH: (989) 673-8733 | FAX: (989) 673-5886 PH: (248) 619-1616 | FAX: (248) 619-1717 engineeredtools.com Chisel method: In this process, a gear is chamfered with the first tool. Then infeed. The desired chamfering is obtained specially formed chisel is used for chamfering. the direction of tool rotation is changed, the after a few turns. The chamfer process itself The spacing between the teeth is generally position tool/work piece is adjusted again, is chip-free. The material removed from the continuous in this case. and the second tool chamfers finally the plane sides is then cut off by deburring with a Milling with chamfer hobs: In this other side of the gear. simple tool, such as turning tools or file discs. case there are two additional disk shaped Rotary chamfering and deburring: In All the processes listed have their tools mounted on the hob spindle. After the this process, a specially formed gear-shaped particular areas of application. For large- hobbing process, the chamfer tools are shifted tool engages with the work piece. Their axes series production, however, in addition to the into working position. The first side of the are parallel and there is only a radial plunge shapes and qualities that can be produced, the determining factors include processing times, tool cycle times, and automation options. Rotary chamfering and deburring has therefore assumed the dominant role in

Fig. 2: Different styles of rotary chamfering tools.

Fig. 3: Principle of rotary chamfering.

34 gearsolutions.com Fig. 4: Working chamber of a hobbing machine with integrated chamfer/deburring unit.

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OCTOBER 2013 35 the automotive and motorcycle industry, and we will now examine it in more detail. The Tool The technology of rotary chamfering and deburring is primarily integrated in the tool itself. It is adapted to the specific processing task and is therefore work piece-specific in most cases. The diameter of the tools is generally between 150 and 200 mm. It is beneficial to choose a prime number as the tooth count. The range for the module that can be chamfered is about 0.8–5 mm. The rotary chamfer tools are made out of high-speed steel dedicated for cold forming operations. Especially for dry chamfering, it is recommended that the tools utilize state-of- the-art coating materials (Figure 2). Both sides of the tooth must generally be deburred and chamfered. As such, the tool consists of two chamfering wheels. These are combined into a compact unit by the Fig. 5: Chamfer shapes used in practice. synchronization gear in the middle. During the production operation, the chamfering has the tendency to flow to the plane faces of chamfer form and quality. Since the wheels do the shape-forming work to achieve the gear or in the tooth gaps. synchronization gear is narrower than the the chamfers. Because rotary chamfering is a The synchronization wheel ensures their work piece by twice the desired chamfer non-cutting operation, the squeezed material exact guidance and this results in consistent width, the flanks of the chamfering wheels

36 gearsolutions.com will engage in those of the work piece during The deburring machines or units synchronization of the driven work piece radial positioning. The synchronization gear are relatively simple and consist of two and a driven chamfer tool. This has the also fills in the tooth gaps of the work piece, parallel spindles whose center distance advantage that the tool and the work piece preventing material from penetrating the gap. is reduced during processing. It does not can come faster into mesh and the risk of For special applications, the tool package matter whether the work piece or the tool is damaging the tooth tips during the plunge can be modified. If the chamfering quality driven. The direction of revolution during motion is greatly reduced. requirements are lower, it is sufficient to the chamfer process is normally constant, Speeds generally range from 100 to 150 replace the synchronization gear with a but there are also solutions in which the rpm at the tool, and the processing itself spacer disk. This is particularly the case direction is changed during the operation. takes only two to four seconds. The material if shaving is to be done afterwards or if It is also possible to have an electronic pressed to the face by the chamfering process chamfering is carried out between two cuts during hobbing. The synchronization gear can also be provided with a burnishing sector. This means that over the space of about 180 degrees, it is wider than the work piece and ground hollow in the direction of the flank lines. The result is that only those zones on the tooth flanks of the work piece are contacted, in which a secondary device can enter the tooth gap (Figure 3). These minimal but sharp secondary burrs are then rolled down by the burnishing sector. The remaining sector of the tool then handles the chamfering work. This variation is especially practical for subsequent hard finishing of the tooth flanks. If the secondary burrs are not removed, they will be extremely hard and sharp after hardening. To protect hard finishing tools such as grinding wheels or honing rings, it is essential to remove them. The Machines Rotary chamfering and deburring can be carried out either with individual machines or by units integrated into hobbing or shaving machines. In the past it was common to have a separate machine for hobbing or shaving and an additional stand-alone machine for chamfering and deburring. This has changed in recent years. Most of the modern machines are now equipped with an integrated chamfer/ deburr unit, and for good reason. Because floor space is expensive, it is increasingly important to minimize the footprint of the equipment. An integrated chamfer unit does not need any additional floor space because it is fully integrated into the base machine (Figure 4). In addition, the cost of an integrated chamfer/deburr unit is significantly lower when compared to a stand-alone machine. This can be easily explained, because the control, the chip removal, the lubrication, and the power supply from the base machine are utilized. In addition, the automation between the two processes is far simpler.

OCTOBER 2013 37 is then cut off in the last work step by chisels or deburring disks Tool Reconditioning positioned by spring force. This compensates for the width tolerances Roller deburring tools can be reconditioned about 3 times after use. of the work piece. The positioning itself can be done using a Generally, the tool life when processing an automotive gear should controlled axis or even hydraulically. be up to 10 million work piece teeth when using coolant. When dry processing, a tool life of about 2.5 million teeth can be expected. Chamfering Shapes If the costs are converted into cost per work piece produced, it is In all cases, at least the sharp front edge should be provided with quickly apparent that the cost per work piece for chamfering with a chamfer. However, this is the exception, since generally both the the described deburring process is low. However, it is equally obvious sharp and the blunt edge must be chamfered. The corresponding that the process can only be cost-effective when working with large design of the tool permits a variety of chamfering shapes to be unit volumes, that is, in series production. obtained with a defined chamfering angle (Figure 5). Experience shows that a comma-shaped chamfer down into Summary the root of the tooth is recommended when chamfering on both The chamfering and deburring of gears is often an undervalued sides. However, a parallel chamfering shape can also be produced. process in gear production, but it has a great influence on the usage Normally, the chamfering angle at the foot of the tooth is about 45 characteristics of the work piece. It is important to distinguish degrees. Measured from the flank, it should ideally not exceed 30 to between the processes of chamfering and deburring, although 35 degrees. Here, up to module 5 mm, a chamfering width of less in practice they are nearly always used together. In large-series than 0.7 mm should be the goal. The size of the chamfer is thereby production, rotary chamfering and deburring is the process most distance checked less than 90 degrees to the gear faces. frequently used, because it is fast and cost-effective.

about the author:

Dipl. –Ing. (Univ.) Karl Schäferling is director of product management: shaving, honing, chamfering, and deburring for Gleason Corporation. In the past, he has held positions such as: development engineer for Hurth Company, Munich; head of the Tooling Business Unit, Gleason-Hurth; and member of the general management Gleason-Hurth. He has studied at the University for Applied Sciences at Aalen and the Technical University of Munich.

38 gearsolutions.com CLARKE GEAR COMPANY The QUIET company with more Gear technology per square foot than you’ll find anywhere. #1 in Service. • CNC Gear Grinding • CNC Hob Sharpening • Serrations • Face Gears (AGMA CL.15) • CNC Gear & Hob Inspection • Sprockets • Internal & External • CNC Gear Cutting • CMM Inspection Service • Spur to 12” Diameter • CNC Machining • Crown Gears • Helical • CNC Gear Analysis • Splines • Worms ISO 9001:2008 Certified: AS9100:2009/2012 AS9104/1:2012 CLARKE ENGINEERING, INC. Since 1954 PH: 323-877-7590 • 818-768-0690 • FAX: 818-767-5577 60Years 8058 LANKERSHIM BLVD. • N. HOLLYWOOD, CA 91605 of EMAIL: [email protected] • www.clarkEgear.com GEARS Gear Up with Clarke Toll Free: 888-277-GEAR (888-277-4327) Go Big, Go Indexable

Advanced carbide insert technology meshes with increased demand for large gears.

By Todd Miller Indexable carbide inserted tooling continues to push large gear productivity. As manufacturers of big gears are further pressured by increased production demands from key industries, including energy, they strive to meet such requirements through faster machining speeds and feeds, yet still maintain high levels of quality.

Gear shops have used indexable carbide inserted speed and more aggressive machining leads to greater cutting tools for more than three decades. However, reductions in cycle time, up to four to eight times faster it is because of recent advancements in the tooling, than those of HSS tooling. And when worn, indexable specifically for gear hobbing and gashing operations, carbide insert tools require only indexing or replacing that gear makers can now achieve even greater of the inserts. productivity and higher quality than ever before, and Additionally, large gear tooling, for the most part, with more tooling options to choose from, especially in requires made-to-order specials, and carbide insert Iterms of geometries and coatings. technology is especially advantageous in that it affords a In most instances, indexable carbide inserted tooling nearly infinite level of customization possibilities. With gives gear shops longer tool life—often four hours an indexable inserted gasher, for example, cutters can or longer as compared to the one or two with be produced for roughing, semi-finishing or finishing. solid tooling—and increased cutting speeds for more The inserts can be customized to the exact gear tooth aggressive machining to reduce cycle times. Indexable geometry or for simple roughing. And by starting fresh carbide insert tools also provide multiple cutting edges, each time, rather than wearing down and then having which, depending on the gear teeth profile, allows a to regrind the cutting surface, the inserted gasher offers shop to flip cutting edges from one side to the other, precise repeatability and accuracy. thus increasing tool efficiency. A major new development in this area is twin-start On the cost savings side, the tooling requires an indexable carbide insert gear hobs, tools that take initial investment of cutter bodies, which, in some cases advantage of the increased power and speed of modern one cutter body can be used in multiple applications CNC gear-cutting machines to achieve increased by simply changing out the inserts, depending on productivity. This new solution, with two half helixes what type of job is required. These inserts can also on the same gear hob module, allows for running at be rotated so that multiple cutting edges are utilized. feedrates that are twice as fast as those of a single helix Another opportunity for cost savings is that large design. Shops can thus reduce gear manufacturing cycle gear manufacturers can opt out of using solid carbide times by half while still maintaining the highest possible tooling, which can be prohibitively expensive or quality levels. even impossible to construct for certain large gear In customer application testing, Seco Tools applications, yet still reap the benefits of increased successfully slashed the production cycle time of a large productivity from carbide with the more cost-effective seven-foot, module 12 gear ring from 22 hours down indexable inserts. When compared to solid high-speed steel (HSS) or cobalt gear tooling, indexable carbide inserted tools not only allow for much higher cutting speeds, but also help reduce the amount of required tooling, again saving cost. For example, a user is able to run a solid HSS tool at perhaps 70 to 100 surface feet, depending on material. As the tool wears, cutting accuracy diminishes, and the tool must be re-ground and re-coated. This fact alone often means that shops will likely have three or more of the same solid tools available for a job—one tool in service, one on the shelf ready to go and one or more out being re-ground and re-coated. For some shops, it is common to inventory up to 10 of the same tools just to ensure that production keeps running. Indexable cabide inserted tooling, on the other hand, would allow for cutting speeds of 500, 600, perhaps Fig. 1: This twin-start indexable carbide-insert gear hob takes even 900 surface feet. This dramatic increase in advantage of the capabilities of modern CNC gear-cutting machines.

OCTOBER 2013 41 to only three hours with Seco’s latest twin- start indexable carbide insert gear hob. This equated to a more than 85 percent reduction in time over the previously used HSS hobs. Seco has also conducted extensive development work and testing in regards to heat and thermal cracking of gear cutting inserts, especially with their use in gashing operations. In those operations, for example, radial engagement of inserts is very light, while the cutters are large in diameter, and shops tend to opt for as tough an insert grade as possible. The problem with that approach, however, is that tougher insert grades are less wear resistant, which shortens the insert life. The problem in running harder grades is they are more susceptible to thermal cracking, once the coating cracks, heat will Fig. 2: This new solution allows for feedrates twice as fast to reduce gear manufacturing cycle times by half. transfer into the substrate and eventually cause the insert to fail prematurely. coating provide an effective combination technology, machine tool capability, in As a result of its research and of toughness to prevent thermal cracking some instances, can prevent optimum development, Seco has achieved what it and high wear resistance for long tool tool performance and thus limit machine believes is the perfect insert balance using life—together with high-speed capabilities. capacity as well. Machines must have its Duratomic coating process. Inserts Gear makers should note that no matter high power and rigidity to run twin-start with a tailored substrate and Duratomic how advanced the indexable carbide insert indexable hobs, for example.

42 gearsolutions.com drive demand for large gears. There are also many other industries driving that demand such as mining and construction, oil and gas and marine, to name a few. Indexable carbide tools are an excellent, cost-effective fit for this growth, offering increased machining speed and productivity never before achieved in large gear cutting. This surge in demand, and the resulting push in research and development of these high-end tools, suggests they are poised for a sustained resurgence in the marketplace.

about the author:

Todd Miller is the manager of rotating products for NAFTA at Seco Tools, responsible for solutions and applications Fig. 3: This twin-start indexable carbide-insert gear hob reduced significantly reduced production cycle time. involving face, square shoulder and disc milling. Todd and his team of product Unfortunately, there exists a great deal of hobs, this is much less common due to the experts are dedicated to providing a older equipment in the marketplace today high cost of that tooling. Indexable tooling consistent, high-level of support to Seco customers throughout the United that has been around since World War II. can be applied in these instances, but some States, Canada and Mexico. For more Shops with such machines are often restricted care must be taken when selecting tools. information, visit www.secotools.com. to using only HSS or powdered metal cutting The global push for clean energy in the tools. While some will also use solid carbide form of wind turbines will continue to

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OCTOBER 2013 43 Cost Reduction Using Powder Metal for Pump and Metering Gears

The powder metal process provides engineered components in just about every industry today, especially producing high quality gears of all types. The following article outlines just one application segment: precision pump and metering gears from powder metal.

By Bob Aleksivich and Ernie Wheeler Powder Metal (PM) gears are used in pumps across a wide spectrum of industries. These include lube pumps for power transmissions in automobiles and heavy trucks, off-road and agricultural vehicles, the food industry, hydraulic lifts, metering/dosing fluids, and moving chemicals. (see Figure 1). PM gears are used in these industries to lower cost without sacrificing quality in the pump application and because of the many design options available in the development of the tooth forms and root radius.

There are many raw materials available for producing PM pump gears. They range from low/medium carbon steel in lower pressure pumps, to the higher-carbon alloyed steel materials that some pumps require for Phigher pressures, optimum gear strength, and excellent wear characteristics in applications requiring long life cycles. It is very important that the PM manufacturer know all the functions of the pump, especially the operational requirements and any special fluids to be used in the pump or metering operation. The PM producer can specify the exact gear material by the critical properties needed. Then, with the appropriate process defined, the gear set will have what is necessary to ensure the success of a PM conversion from other gear manufacturing processes. Strength of PM materials has advanced today for PM gears applications. Using lower-cost, conventional

processing methods, it is now possible to produce gears Fig. 1: PM gears shown in a pump housing. with tensile strength over 200,000 PSI with yield strengths near 190,000 PSI. For a long gear life, one thickness varying (see Figure 3). In most cases, one can also expect micro hardness of PM gears after heat set of powder metal tooling can produce all the series treat to be R/C 58-60 when produced from one of the lengths, keeping your upfront tool cost minimal with many alloy steels available to the manufacturers today. an attractive ROI. Annual volumes play a large part Again, it is very important to advise the PM vendor of in the tooling payback equation, but because of the all your pump’s requirements. expected cost savings over gears produced by other In the PM process the gear tooth is not cut from a processes, even annual volumes as low as 1,000–2,500 blank, but rather pressed in a forming die (see Figure pieces a year have been tooled, replacing a current 2). The raw material is transferred over and dropped cut steel gear, cut forging, one being preformed with into the die, which contains the shape of the gear teeth shaved, or a machined casting. Not all PM form. Punches enter the die from the top and bottom, pump gear producers quote volumes this low, but a compacting the shape and size of the gear. The PM thorough search will find those that will. Of course, process is capable of producing a gear with up to an the PM process is capable of producing very high AGMA Class 8 quality, without the cost of cutting volume production also, especially in the OEM and or roll forming each tooth separately, or without any aftermarket automotive industry. further secondary operations needed to define the Another cost-saving advantage of a PM pump gear gear form. Unlike some processes, most of the PM is that the gears’ ID shape—such as a spline, keyway, manufacturers charge you for the initial set of tools d-shape, or a hex shape—does not have to be broached only, then maintain those tools for the life of the part or milled at a very high cost. The same method used design, or until a possible change is made to the gear by PM tools to form the teeth also applies to the ID that requires new or partial tooling. shape. Many different ID designs are possible, and can Most gear pumps use a family of gears—a series be molded in on a core rod at standard dimensional of gears with different lengths to control the flow of PM tolerances. Should you need a closely-toleranced the pump. The design features are all the same on ID, as many gears do, the shape of the ID (e.g. a round this family of gears, with the exception of the gear bore with a keyway) is molded in, but also may need a

Fig. 2 (left): A typical set of PM tooling for producing pump gears. October 2013 45 A Better Way TheThe “NDG”“NDG” MethodMethod NewNew Power fforor yyourour Gear Measuring & Inspection Systems

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Fig. 4: Typical tolerances possible on a PM pump gear

final turning or a grinding operation to escaping under the gears, increasing the hold the precision bore tolerance. Some pumps efficiency. For these reasons, the of the typical tolerances that can be held edge quality is very well controlled in using the PM process, including some PM pump gears. Discuss this area with secondary finishing operations, are shown your PM vendor to ensure you have the in Figure 4. proper process applied to the gear tooth Gear designers and product engineers edges/corners. There are multiple ways find they have a much greater opportunity to approach the edge definition, so it is for optimum and consistent flow rate, important the PM vendor knows what is • With our state of art NGD method increased tooth strength, and pump expected of the pump. it is possible to measure the any external and internal Gear from operational noise reduction using PM Powder metal pump gears wear very small as Module 0.2 or larger size pump and metering gears instead of well, and with the proper material even over 30000 mm OD. gears that have been hobbed. There is specified the user can expect that the • User Friendly virtually no limit in the involute profile gears will last through their full life cycle. design/shape where the objective is noise Properties such as pump pressure, RPM, reduction in the meshing of the two shaft- types of fluids used, any special conditions mounted gears. For added tooth strength such as excessive hot or cold temperatures, in higher-pressure pumps, a full fillet or high-pressure starts should be discussed radius is possible at the root diameter, and with a PM vendor. Again, how many also includes more options for the tooth cycles the PM gears can withstand varies USA Office form starting up from the root radius based upon the above parameters, the Tokyo Technical Instruments USA Inc. of the gear teeth. The tooth tip can be gears raw material chosen, the heat treat 297 Kinderkamack Rd., #133 a full radius design, a flat sharp tooth process applied, and any post heat treat Oradell, NJ 07649 Ph: 201-634-1700 tip design, or somewhere in between. options needed. Fax: 201-262-2187 Whatever the design application requires Dependent upon the process and the is likely available with PM gears. properties needed, PM Manufacturers Japan Headquarters Edge quality of the gear teeth is also have many options in the heat treat process Tokyo Technical Instruments Inc. Main Office Ph: +81-3-3726-4188 important, whether you use the gear set to choose from. Not every company offers Factory Ph: +81-284-73-1733 to seat in your housing or want a more all of these, but some of the heat treat See Details defined corner edge size that does not options include: through-hardening, case www.tti-geartec.jp dig into the pump housing. A crisp edge hardening, induction hardening, sinter or minor break prevents the fluid from hardening, and post cryogenic treatment

46 gearsolutions.com of the gears. Make sure the vendor knows the pump application’s working with a potential PM vendor to establish the properties exact function so they can develop a gear that not only performs your pump application needs, a quality set of gears will be to your requirements, but also has been given every cost-effective produced that perform in your pump issue-free. At the same time, consideration available when using PM Gears. high-quality PM pump gears offer excellent cost savings when From the information above, you can now see that by using compared to other processes. powder metal pump and metering gears, produced to the High quality powder metal pump gears are being made by the customer’s exact precision tolerances while using one of the millions. In a globally competitive market today, PM pump gears PM industry’s wide varieties of materials, can ensure your offer the cost savings needed to stay ahead of your competitor pumps meet the most strenuous performance requirements. After and the quality to ensure current gear tolerances are met. They provide many material options to ensure gear performance, and a high-quality process in place to ensure the life expectancy of the pump. Powder metal should be shaping your current and future gears.

about the author: Bob Aleksivich is co-owner of Vision Quality Components, Inc. Bob has over 26 years of Powder Metal Engineering Management experience in tool design, process, and new product development. He has been engineering powder metal components since 1983. Ernie Wheeler is director of sales of Vision Quality Components, with over 35 years Powder Metal experience in engineered product field sales and new customer business development. This year, Vision celebrates 10 years in business—both Bob and Ernie have been there from day one.

Fig. 3: A family of gears made with one set of PM tools.

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AWEA_Offshore_7x4.875.indd 1 9/20/13 12:21 PM October 2013 47 Squeezing Productivity Out of Gear Milling Operations

When we talk about the broad and common operation of slot milling, the name of the game is chip thinning.

By Aaron Habeck Gashing in gear milling applications is basically a slotting operation. Whether it is a gear tool such as a CoroMill® 170 or a standard slotting cutter such as the CoroMill® 331, the aim is to apply the correct feed rate to take advantage of chip thinning. When a programmer or operator fails to take chip thinning into consideration, there will be a loss of productivity and tool performance.

Therefore, it is important to apply the same chip- thinning principals that we use in slot milling, with the appropriate formulas and calculations, to squeeze every last drop of productivity out of many gear milling operations. GEvery Last Drop Gashing or disk milling internal and external gear teeth can be an economical and productive way to approach gears. One way to optimize productivity in gashing is to understand the basics of chip thinning.

Manufacturers give two feed recommendations: fz,

which is the programmed feed, or hex, which is the maximum chip thickness. When a cutter is set to a radial engagement of cut equal or greater than its

radius, feed per tooth ( fz) and maximum chip thickness Figure 1: When radial engagement is less than radius, chip thinning occurs. (hex) will be equal to each other. However, when the radial engagement is less than the radius, chip thinning the cutter diameter, there’s a relatively large amount of occurs (Figure 1). The second condition is always the chip thinning – a factor of 1.46 to 1.75 or a 46 to 75%

case in gashing operations due to the relatively small increase. Use the table below to calculate fz based on the

radial engagement of a gear tooth compared to the cutter diameter, module size and the proper hex value cutter diameter. for the insert.

Feed per tooth – fz is a basic value for calculating the The chip thickness is an important consideration machine’s programmed feed rate. It must calculated when deciding the feed per tooth, to ensure that the most to optimize operations with respect to maximum chip productive table feed is employed. The hex is used to

thickness, or hex. This value is a result of the cutter calculate the fz in the chip thinning formula. engagement as it is related to cutter diameter. When conventional slotting with a CoroMill® 331 using a 250mm (10.0”) diameter, for instance, you could have multiple depths of cut. This can lead to lots of variables in chip thinning equations. But in gear milling, each cut is a known value, because you’re cutting a tooth Where, DC = cutting diameter size that has a constant depth. With a 250mm (10.0”) And ae = radial engagement gashing disk for a module 12 (DP 2.1) gear tooth, we can use a constant multiplication factor. Therefore, a Example 250mm diameter module 12 cutter running at

reference chart can be used based on the module (tooth) hex of 0.3mm (.012”) size, the cutter diameter and the multiplication factor. In the example above, the tooth depth will be roughly

27mm (1.063”) when using a dedendum (hf) of 1.25*mn. This value can change slightly depending on the ® operation. Roughing cutters such as a CoroMill 170 Using the chart fz = 0.30 *1.61 = 0.48 would leave some finishing stock on the root diameter. Therefore, the multiplier could be slightly less. A Ignoring this chip thinning formula, there is a finishing or semi-finishing tool would cut the tool to full chance that the feed rate will be too low for the insert depth. In addition, this value can change based on end geometry or edge preparation. The general rule in

user design requirements. A common cutter diameter milling is to avoid going below .076mm or .003” hex for this size tooth would be 200 to 300mm (8 to 12”). as there will also be some tolerance on the position /

By having such a small radial engagement compared to run-out in the tool body. Too low a hex value can result

October 2013 49 Module 10 12 14 16 18 20 22 24 26 28 30 Tooth Depth (mm) 22.5 27 31.5 36 40.5 45 49.5 54 58.5 63 67.5 150 1.40 1.30 1.23 175 1.49 1.38 1.30 1.24 1.19 200 1.58 1.46 1.37 1.30 1.24 1.20 1.16 1.13 250 1.75 1.61 1.51 1.42 1.36 1.30 1.25 1.22 1.18 300 1.90 1.75 1.63 1.54 1.46 1.40 1.35 1.30 1.26 1.23 1.20 350 2.04 1.87 1.75 1.65 1.56 1.49 1.43 1.38 1.34 1.30 1.27 400 2.17 1.99 1.86 1.75 1.66 1.58 1.52 1.46 1.42 1.37 1.34 Cutter dia. (mm) 450 2.29 2.11 1.96 1.84 1.75 1.67 1.60 1.54 1.49 1.44 1.40

500 2.41 2.21 2.06 1.93 1.83 1.75 1.67 1.61 1.56 1.51 1.46

Table 1: Multiplication factor for hex to calculate fz

compensation should still be used to achieve the highest productivity then adjusted for the correct surface finish. While there is chip thinning due to the radial engagement, there is also chip thinning as a result of the lead (entering) angle of the tool. However, the compensation is typically built into the cutter design instead of the feed rate. Most manufacturers will use half to a third as many effective flank inserts as the number of effective root inserts. As an example, a 350mm diameter CoroMill® 170 roughing cutter has 8 effective root inserts, with 2 sets of 4 effective flank inserts to achieve the full depth (Figure 2). This

means the flank insert with have twice the feed rate (fz) of the root inserts. This is needed to compensate for the 20° angle of the tool.

Using this tool: 8 effective root inserts running with a fz value of 0.53mm (.021”) and hex of 0.30mm (.012”). The flank inserts will have a fz of 1.06mm per insert. Using the SIN of 20 degrees (.342), which is the pressure angle of the tool, the 4 effective flank inserts will have a hex value of 1.06 * .342 / 1.75 = .21mm (.008”). The 1.75 in the calculation is for the radial chip thinning and can be found in the table for a Module 12 350mm cutter. In the end, it is about maximizing the output of gear milling. Without taking into consideration chip thinning in gashing operations, especially roughing, there will a risk of lost productivity and poor tool performance. Figure 2: A 350mm diameter CoroMill® 170 roughing cutter has 8 effective root inserts. about the author: in more of a rubbing effect than actual cutting, generating additional heat in the process. This inevitably creates a loss in tool life and productivity. Aaron Habeck is marketing project manager for Sandvik Maximum chip thickness (h ) recommendations can be found in the Coromant Col, Fair Lawn, N.J. For more information about the ex company’s CoroMill products, call 1-800-SANDVIK, or log on manufacturers’ catalogs or on their website. to www.sandvik.com. In finishing operations, the scallop height on the flank or root will restrict the feed rate to achieve the desired finish. The chip thinning

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

OCTOBER 2013 53 Gleason 608 & 609 Rougher & Finisher REF#107 Barber Colman 6-10, CNC, CRt 5 Axis, 6” Dia, 10.5” travel, 6 DP REF#103 FELLOWS #36-6 Max Dia 36” 6” Face, 3 DP REF#103 Gleason 7A, 7”PD Helical Motion, Gears & Cams REF#107 Barber Colman Hobber Type T REF#103 FELLOWS #HORZ Z SHAPER, 10 x 6 Dia 27.6 Face 8.5” REF#103 Gleason Cutters, 3” to 25” in stock, 1000 REF#107 Barber Colman model #14-15 Gear Hobber, horizontal Heavy Duty REF#103 FELLOWS #4GS & 4AGS, 6” Dia, 2” Face, 4DP, ’68, Ref.# Several REF#103 Barber Colman Model #16-36 GearHobber REF#103 FELLOWS #624A, 18” Max Dia, 5” Face REF#103 Barber Colman Model #16-56, 16” dia, 56” Face, adj. Air Tailstock REF#103 FELLOWS #7, #7A, #715,# 75A, #715, #725A, 7” Dia, 0-12” Risers, GEAR GRINDERS Barber Colman Model 2.5-2 gear hobber, 2” length Manual Dresser REF#103 Several Avail REF#103 #27, #137, and #463 Gleason Hypoid Spiral Bevel gear grinder G&E Model 5.2 CNC Internal Gear gashing head REF#103 MICHIGAN #18106 SHEAR-SPEED GEAR SHAPER,14" Dia, 6"Face REF#103 generating Cams (2 full sets) REF#102 Jeil JDH-3, Gear hobber, Max Dia 31.5”, 3DP, 22.8 Table Diameter REF#103 FELLOWS Model Z Shaper, 5" Stroke, ‘50’s REF#103 Springfield Vertical Grinder, 62" Table, #62AR/2CS, 3.5A Rail Type, 70" Swing REF#102 Jeil JDP-2, Gear hobber, Max Dia 26”, 4 DP, 19.5” Table Dia, Differential and tailstock STAEHELY SHS-605, Gear Shaper REF#103 REISHAUER ZA, Gear Grinder, 13" Dia, 6" Face, Strait & Helix REF#103 REF#103 FELLOWS #6, #6A, #61S, From 18”-35” Dia, 0-12” Risers REF#103 GLEASON #463, 15” Dia REF#103 Liebherr ET 1802, Internal Gashing head, Fanuc 16i Control, 98”Max dist 17” Face REF#103 FELLOWS #8AGS Vertical Gear Shaper, 8” Dia, 2” Face, 6-7 DP REF#103 Hofler model Rapid 2000L, CNC Grinder, Max OD 78”, CNC Dressing REF#103 Liebherr L-402 Gear hobbing Machine, New 1977 REF#103 Matrix model 78, Reman CNC Thread grinder, 24” Dia, 86” grind Length, 106 between TOS OHA50 CNC 5 20” Dia 5” Face REF#105 Liebherr LC 752, 6 Axis CNC Hobber, Max OD 29.5”, Max Face width 23.6” REF#103 centers REF#103 Fellows 36-6 Shaper (2) 12.5" Risers 6" Stroke Mint YR 1969 id 3616 REF#106 Micron Model 120.01 w/bevel Cutting Attachment, New 1975, 1.6” dia, 25.4 DP REF#103 Mitsu Seiki Model GSW-1000 Gear Grinder REF#103 Fellows 36-6, shaper W/6” riser, change gears REF#106 Nihon Kakai Model NTM-3000, Spline Hobbing Machine, Max dia 400mm, 3150mm between Reishauer RZ 362 AS, CNC Grinder, Max Dia 360mm REF#103 Magg shaper SH4580-500S, 206”dia. 26” face REF#106 Center REF#103 Sundstrand/Arter Model D12 Grinder REF#103 Magg shaper SH250, 98” dia. 26” face REF#106 Pfauter P900 Reman and Recontrolled, Max OD 120” REF#103 Teledyne-Landis Gear Roll Finishing Machine, 5” Diam, 42k lbs Rolling Force REF#103 Fellows #10-4,7” riser yr 1980 REF#106 Pfauter Model PE125 CNC Gear hobber REF#103 Reishauer RZ301AS CNC, 13” Measuring System (3) REF#107 Pfauter model PE300 CNC, Max OD 12”, Max gear face 15”, 3 DP, 6 Axis REF#103 Fellows 3”, 6”, 7”, 10”, 18”, 42”, 100, Some CNC REF#107 Reishauer ZB, 27.5” PD Gears, Coolant REF#107 Reinecker Heavy Duty Gear Hobber REF#103 Scheiss Model RF10 Horizontal Hobber, 60” dia, 144” face, 180”cc, 8 DP REF#103 G&E 96H, roughing & finishing 104” dia. REF#106 GEAR DEBURRING/CHAMFERING/POINTING GEAR RACK MILLERS/SHAPERS TOS FO-16 single index 80” dia. Yr 1980 REF#106 CROSS #50 Gear Tooth Chamferer, 18” Dia, Single Spindle REF#103 MIKRON #134 Rack Shaper, 17.4" Length, 1.1" Width, 16.9 DP REF#103 Craven spline & pinion hobber 36” x 96” REF#106 REDIN #20D, 20” Dia, Twin Spindle, Deburrer/Chamfer REF#103 SYKES VR-72 Vert Rack Shaper, 72" Cut Length, 4DP, 4" Stroke, ‘80 REF#103 G & E 48H 48” dia. Diff, OB, change gears REF#106 Fellows 4 – 60 Rapid Traverse, 2 Cut REF#107 Pfauter hobber P-1800 70” dia. 29” face yr 1980 REF#106 SAMPUTENSILI #SCT-3, Chamf/Deburrer, 14” Dia, 5” Face, ‘82 REF#103 Lees Bradner 7VH, 8”PD, 10” Face, , Magnetic Chip Conveyor , Hob Shift REF#107 SAMPUTENSILI #SM2TA Gear Chamfering Mach, 10” Max Dia, (3) New ‘96 REF#103 Lees Bradner 7VH, 8”PD, 4PD, Magnetic Chip Conveyor, Hob Shift REF#107 REDIN #24 CNC Dia 4” Setup Gear Deburring REF#103 GEAR THREAD & WORM, MILLERS/GRINDERS CROSS #60 Gear Tooth Chamferer, 10” Dia, Single Spindle REF#103 Mitsubishi Model GH300, 15.7”, 3 DP, Differential, 2 Cut REF#107 BARBER-COLMAN #10-40, 10" Dia., 40" Length, 4 DP REF#103 FELLOWS #100-180/60 CNC Max Dia 180”, Single Spindle REF#103 Tos 32A, 320mm Gear Dia.,3.6 DP, Differential, 2 Cut REF#107 EXCELLO #31L, External Thread Grinder, 5" OD, 20" Grind Length REF#103 Gleason 775 8”PD, High Helix Head, Infeed, Very Light Use REF#107 CIMTEC #50 Finisher REF#103 EXCELLO #33 Thread Grinder 6” Dia 18” Length REF#103 Barber C. 16-15, 7 ½” Hob, Crowning, Differential, 2 Cut REF#107 CROSS #54 Gear Deburrer, 30” Dia, 18” Face REF#103 HURTH #KF-33A Multi-Purpose Auto-Milling Machine 88” REF#103 Barber Colman 14-15, 2 Cut, Fast Approach, 4” Bore REF#107 RED RING #24 Twin Spindle Dia 4” REF#103 LEES BRADNER #HT12x102, Extra Large Capacity REF#103 Barber Colman 16-36, Type A – Very Good, Double Thread Index REF#107 GLEASON GTR-250 VG CNC 5-Axis REF#103 LEES BRADNER #HT 12"x 144" Thread Mill, 12" Dia, REF#103 G & E Model 48HS 48”PD, 18” Face, 2.5 DP REF#107 Gleason- Hurth Model ZEA 4, Max Dia 250mm, Max Module 5mm REF#103 LEES BRADNER # LT 8” x 24” 8” Dia REF#103 Redin Model 36 universal Chamfering and Deburring Machine, Max OD 36”, Twin spindle, HOLROYD 5A 24.8 “ Dia REF#103 LEES BRADBER WORM MILLER REF#103 Tilt table REF#103 Dranke CNC Internal Ball Nut Grinder REF#107 GEAR SHAPERS Samputensili SCT3 13.7”, SM2TA 10”, (5), 2003 REF#107 FELLOWS #10-2, (10” Dia), 2” Face REF#102 Mitsubishi MA30 CNC, 11”PD, Fanuc, Powermate, 1999 (2) REF#107 FELLOWS #10-4, (10” Dia), 4” Face REF#102 GEAR TESTERS/CHECKERS (incl CNC) FELLOWS (200) 10-4 / 10-2 Shapers REF#102 FELLOWS (1) RL-600 Roll Tester s/n 35814 REF#102 FELLOWS (1) 50-8 Hydrostroke Shaper s/n 36607 w/ GEAR Honers FELLOWS (1) 24H Lead Checker s/n 32289 REF#102 6 axis 16iMB Fanuc (2009) REF#102 GLEASON (1) #14 Tester s/n 31907 REF#102 Kapp #CX120 Coroning 4.7” Dia REF#103 FELLOWS (1) 20-8 Hydrostroke Shaper s/n 35932 w/ GLEASON (1) #6 Tester s/n 19316 REF#102 Red Ring GHD-12, 12” Dia, 5.5 Stroke REF#103 6 axis 16iMB Fanuc (2009 REF#102 FELLOWS (1) 20 M Roller Checker REF#102 FELLOWS (1) #7 125A Face Gear Machine REF#102 Red Ring GHG, 12” Dia, 5.5 Stroke REF#103 FELLOWS (1) 20 M w/ 30” Swing Roller Checker REF#102 FELLOWS (2) #3 Face Gear Machine REF#102 Kapp #VAC65 Coroning 10” Dia REF#103 FELLOWS (1) #8 Micaodex s/n 36279 REF#102 (1) 4ags with adjustable Helical Guide s/n 30634 REF#102 David Brown #24 Worm Tester REF#103 (1) #7 125A adjustable Helical Guide REF#102 Gleason #4, #6, #13 and #17 Testers REF#103 GEAR SHAVERS FELLOWS (1) FS630-200 Hydrostroke Shaper s/n 36943 w/ Hofler EMZ-2602 Int/Ext Gear Tester 102” REF#103 6 axis 16iMB Fanuc (2009) REF#102 Red Ring #GCX-24" Shaver, 24” Dia, 33” Stroke REF#103 Klingelnberg #PFSU-1600 Gear Tester-2001 REF#103 FELLOWS (3) Tilt Table 10-4 / 10-2 w/ 4 axis 21i Fanuc Red Ring #GCU-12, 12” Dia, 5” Stroke REF#103 Kapp Hob Checker WM 410 REF#103 Controller (2009) REF#102 Red Ring #GCY-12, 12” Dia, 5” Stroke REF#103 Maag #ES-430 Gear Tester REF#103 FELLOWS (2) Swing-away center support for 10-2 / 10-4 REF#102 Red Ring GCI 24, 12.75” Dia, 5” Stroke REF#103 Maag #SP-130 Lead and Involute Tester REF#103 FELLOWS (1) FS630-170 Hydrostroke Shaper s/n 36732 w/ National Broach Gear Tester GSJ-12 REF#103 Kanzaki model GSP 320 Gear shaver REF#103 6 axis 16iMB Fanuc (2009) REF#102 Oerlikon #ST2-004 Soft Tester REF#103 Red Ring GCU 12 Crowning, 1956 to 1988 (6) REF#107 FELLOWS (2) FS400-170 Hydrostroke Shaper w/ Maag #SP-60- Electronic Tester REF#103 Mitsubishi FB30, 12.2 CNC Fanuc, 1997 REF#107 6 axis 16iMB Fanuc (2009) REF#102 Parkson #42N Worm Gear Tester REF#103 Sicmat Raso 100, CNC Fanuc 16M, New, Guarantee REF#107 FELLOWS (4) FS400-125 Hydrostroke Shaper w/ 6 Vinco Dividing Head Optical Inspection REF#103 axis 16iMB Fanuc (2009) REF#102 Gleason model 511 Hypoid tester Max Dia 20”, max spindle centerline 3.5” REF#103 FELLOWS (1) 20-4 Shaper s/n 35687 w/ 4 axis GEAR GENERATORS Klingelnberg Model PFSU-1600 63” Dia, 1.02 DP, Rebuilt REF#103 21i Fanuc Controller (2009) REF#102 MAAG ES401 Pitch tester With Process Computer REF#103 FELLOWS (1) 48-8Z Shaper w/ 14” throated riser (53” of swing) REF#102 GLEASON #37 Str. Bevel Planer, 6” Dia REF#103 Fellows 12 & 24M Involute, 12 & 24 Lead REF#107 FELLOWS (1) Horizontal Z Shaper s/n 21261 REF#102 GLEASON #496 Straight.& Spiral. 7.5” Dia REF#103 Fellows 36” Space Tester, Hot Pen Guaranteed REF#107 FELLOWS (1) 4-B Steering Sector Gear Shaper w/ 18iMB GLEASON 725-Revacycle, 6” Dia REF#103 Gleason 17A Running or Rebuilt Guaranteed REF#107 4 axis Fanuc controller s/n 34326 REF#102 GLEASON 726-Revacycle, 5” Dia REF#103 Gleason 511, 20” Reconditioned in 2010 Guaranteed REF#107 FELLOWS (1) 36-10 Gear Shaper REF#102 Farrel Sykes Model 12C herringbone max dia 264”, max face width 60” REF#103 Gleason 27, 26”, Guaranteed REF#107 FELLOWS (1) 10x6 Horizontal Z Shaper REF#102 Farrel Model 5B herringbone gear generator. REF#103 Gleason 515, 24” REF#107 FELLOWS (1) 36-6 Gear Shaper w/ 13” riser s/n 27364 REF#102 Gleason 529 gear quench press, Auto cycle 16” Diam, New 1980 REF#103 Gleason 523, 20” Reconditioned, 2010 REF#107 FELLOWS (1) 10-4 Shaper w/ 3” riser w/ 4 axis 21i Gleason 614 hypoid finishing machine, 10.5” pitch, dia 5.25” Max cone dist REF#103 Fanuc Controller (2009) REF#102 Oerlikon/klingelnburg Model C28, Max dia 320 mm, Max Module 7.5 mm REF#103 All Parts for 10-4/10-2 Fellows Gear Shapers REF#102 MISCELLANEOUS Gleason Model 26 Quench press and Hypoid Generator Max OD 16”, Max face Width Air Cylinder FELLOWS #36-8, 36” Dia, 8” Face REF#103 WARNER & SWAYSEY #4A M-3580 Turret Lathe, 28 1/4 Swing, 80” Centers, 12” Spindle Hole REF#103 FELLOWS #100-8 100” Dia, 8” Face REF#103 50/25 Motors, 480/3 Phase, Year 1965 REF#101 Gleason Model 36 Gear Quenching Press, Max Ring 28” OD, 8” Face, Universal REF#103 FELLOWS #612A, 615A, #645A REF#103 Springfield Vertical Grinder, 62" Table, #62AR/2CS, 3.5A Rail Type, 70" Swing REF#102 Gleason Model 450 HC CNC Hypoid Cutter, Face width 2.6”, fanuc 150 Controls REF#103 FELLOWS #10-4, 10” Dia, 4” Face, 4 DP REF#103 GLEASON #529 Quench, 16" Diameter REF#103 Gleason 24 Rougher, Gears, Finishing Tool Holder REF#107 FELLOWS #4A Versa, 10” Dia, 3” Face, 4 DP, New ‘70’s REF#103 Klingelnberg Model LRK-631 Gear Lapper REF#103 12” Gleason, Gears, Gauges Tool Blocks REF#107 FELLOWS #10-2, 10” Dia, 4” Face, 4 DP REF#103 VERTICAL TURNING LATHES AND MORE - Please Check Our FELLOWS #20-4, 20” Dia, 4” Face, 4 DP, ‘70’s REF#103 Gleason 116 Rougher & Finisher (6) REF#107 Website To View Our Entire Inventory REF#103 FELLOWS #3-1,/3GS, 3” Max Dia, 1” Face, Pinion Supp, High Precision REF#103 Gleason Phoenix 175HC CNC – 1994 REF#107 TOS SU & SUS Series Conv Lathes REF#105 FELLOWS #48-6 INTERNAL GEAR SHAPER ONLY,0-72"OD,6" Face REF#103 Gleason 22 Rougher & Finisher (8) REF#107 TOS SUA Series CNC Flat-Bed Lathes REF#105 MAAG #SH-150, 57" Dia.12.6" Face REF#103 Gleason 610 Combination Rougher & Finisher, 1988 REF#107 Change gears for G & E hobber REF#106 PFAUTER #SH-180 Shobber 7" capacity hobbing, 9.45" cap REF#103

54 gearsolutions.com Product SHOWCASE New products, equipment, and resources

Eriez Finishing Mill Unloaders Boost Productivity in Parts Finishing Operations

Eriez® Finishing Mill Unloaders quickly and automatically remove ferrous parts from finishing mill media, helping to improve productivity and efficiency in busy parts finishing operations. Three models are available to match customers’ specific application requirements. All Eriez Finishing Mill Unloaders use a permanent magnet pickup and can be quickly and easily wheeled into position beside the mill and are hydraulically lowered into place. As parts near the surface of the media, they are pulled out by the magnetic field, conveyed up and away from the mill, and pass through a demagnetizing unit before reaching the discharge chute. The Model 58 C/P Mill Unloader is a fully-enclosed magnetic conveyor with permanent magnets mounted on an endless chain revolving beneath a stainless-steel plate. This unit is designed for lightweight parts. The Model 9B-P Mill Unloader utilizes a cleated conveyor belt with a 12-inch diameter magnetic head pulley to pull out parts. Magnetic rails above the pulley hold parts firmly to the belt until they reach the horizontal portion of the conveyor. The most versatile Eriez Finishing Mill Unloader is the Model 9B-DP. This unit can normally remove all parts from a 10-20 cubic foot mill in five minutes or less. As parts are pulled out of the media and carried to the top of a 12-inch diameter magnetic drum, they jump across an adjustable gap to an eight-inch diameter head pulley revolving with a horizontal conveyor belt. Any trapped media falls back into the mill as the parts move through the demagnetizer to discharge. For more information, visit www.eriez.com.

OCTOBER 2013 55 DiaCut CP Punching Oils from oelheld

DiaCut CP punching oils have been developed especially for fast punching machines. They effectively prevent the formation of built- up edges and allow for punching largely without burrs. DiaCut CP punching oils are rolled or sprayed onto the work pieces to be processed. After the operation, the parts are practically free of residue. DiaCut CP punching oils are free of chlorine and heavy metals and practically free of aromatic compounds, so they guarantee the best health protection as well as greatest possible performance.

DiaCut CP 1 A punching oil of highest purity, developed for steel and non-ferrous heavy metals. All of the ingredients have been admitted for contact with food by the American Food and Drug Authority (FDA). DiaCut CP 1 is extremely thin-bodied and evaporates without leaving any residue behind.

DiaCut CP 2 A punching oil with low viscosity and good performance, suitable for steel and copper alloys. It evaporates leaving practically no residue behind.

DiaCut CP 3 A thin-bodied highly effective punching oil with very good EP qualities for the processing of steel and copper alloys. DiaCut CP 3 can also be used as a drawing oil, which leaves practically no residue behind. At the same time, it offers increased protection against corrosion for longer storage of the processed parts.

DiaCut CP 5 A very highly alloyed punching oil that can nevertheless be used for copper alloys (except for very pure copper).

DiaCut CP 6 A highly alloyed punching oil for nickel chromium steel, also suitable as a drawing oil. DiaCut CP 6 is thin-bodied, it evaporates leaving practically no residue behind, and it affords an increased protection against corrosion. It is not suited for copper alloys.

For further information, contact oelheld U.S. at (847) 531-8501 or visit their website at www.oelheld.com.

56 gearsolutions.com UBQ: Universal Batch Quench Furnace. E-Z Series Endothermic Generators. Ultimate in flexibility and versatility. AFC-Holcroft: Strength and Innovation since 1916. Powerful Solutions for the Future.

As a privately owned company with thousands of installations worldwide, AFC-Holcroft is a worldwide leader in the heat treat equipment industry.

One of the most diverse product lines in the heat treat equipment industry: Pusher Furnaces, Continuous Belt Furnaces, Rotary Hearth Furnaces, Universal Batch Quench (UBQ) Furnaces and Endothermic Generators.

Robust construction and long service life, designed for ease of maintenance.

Various global facilities in North America, Europe and Asia for fastest local delivery, service and support.

Get in touch with us today to learn more about how we can improve your production processes and how we can give you the edge over the competition.

For further information please visit www.afc-holcroft.com

AFC-Holcroft USA · Wixom, Michigan AFC-Holcroft Europe · Boncourt, Switzerland AFC-Holcroft Asia · Shanghai, China Phone: +1-248-624-8191 Phone: +41 32 475 56 16 Phone: +86-21-58999100 Award-Winning Universal Vertical Thread Grinder from Mitsui Seiki

Mitsui Seiki has developed the world’s first universal vertical thread grinder, offering many important benefits for customers making precision lead screw type parts. The new VGE60A High Precision Universal Vertical Thread Grinder recently won the Grand Prize in Japan’s 43rd Machine Design Awards competition, sponsored by Japan’s Ministry of Economy, Trade, and Industry. According to Tom Dolan, vice president of Mitsui Seiki USA, Inc., “There’s been a long trend of switching over from hydraulic to electrical power actuation in a variety of important industries such as automotive, aerospace, and robotics. As such, lead and feed screw actuators for electrical power steering, flight control actuators, and automation systems are in increased demand. Along with these market drivers, highly accurate and efficient machining methods for various screws, such as ballscrews, have also been on the rise. Typically, thread grinders have been made the same way for the last 50 years. This new technology changes everything.” Addressing these market forces, Mitsui Seiki developed a completely new, industry-first universal thread grinder design configuration. It offers improved accuracy, speed, performance, and multi-functionality over conventional horizontal thread grinder designs. By granting the Grand Prize, METI acknowledges that Mitsui Seiki has developed a noteworthy machine. The new VGE60A is categorized as a “universal” machine because different grinding operations can be performed. In addition to thread grinding, the machine can now perform spline, gear, OD, surface, and edge grinding operations in a single setup. This can save customers significant production time while improving overall part accuracy. Newly designed features such as an automatic grinding wheel changer, automatic wheel guard, a CNC-controlled wheel dresser (to accommodate various shaped wheels) vastly improve productivity. Infinitely programmable grinding wheel tilt angles from +45 to -90-degrees provide increased grinding application opportunities. The vertical orientation of the work enhances overall precision Elimination of workpiece “sag” is the principle contributor to increased precision. For more information on Mitsui Seiki products and services, visit www.mitsuiseiki.com.

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FABTECH represents every step of the metal manufacturing process from start to fi nish. It’s where new ideas, products and technology are highlighted through interactive exhibits, education and networking. Compare solutions from 1,500+ exhibitors, fi nd machine tools to improve quality and produc- METAL FORMING | FABRICATING | WELDING | FINISHING tivity, and learn ways to increase profi t. REGISTER NOW for the show with a degree of difference.

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November 18–21, 2013 | Chicago, IL Cosponsors: Scan code to fabtechexpo.com | watch video.

58 gearsolutions.com MHI Launches Upgraded ST40A" Helical Gear Shaping Machine

Mitsubishi Heavy Industries, Ltd. (MHI) has completed the development of a new gear shaping machine, the ST40A, capable of cutting a broad array of gears, including helical and cluster gears, with one system. The ST40A's significantly expanded range of cutting applications derives from the first application in Japan of NC programming technology to the relieving motion that prevents interference between the cutter and the workpiece. The new offering made its international debut in the United States with a live demonstration of its capabilities at Gear Expo 2013. The company intends to market the ST40A for a wide spectrum of gear cutting applications for various products including automobiles, construction machinery and aircraft. The ST40A is a totally upgraded version of the ST40, a helical gear-shaping machine requiring no helical guide for each workpiece—achieved through the world's first application of NC technology to torsional motion during the cutting of helical gears. The ST40A has extended the ST40's cutting flexibility even further by incorporating Japan's first NC-programmable relieving mecha- nism and making all seven of the machine's axes fully NC-programmable. This new capability enables the ST40A to accommodate various high-precision cutting applications such as crowning and tapering. In addition, stroke speed has been increased by 20%, from the earlier 500 strokes per minute to 600, enabling high-speed cutting with a focus on productivity. Stroke speed when machining at lower speeds meanwhile has been reduced by 50%, from 60 strokes per minute to 30, enabling secure cutting of hard workpieces. The new machine is also capable of tapering up to 0.3 degrees without use of a tilt table. In these ways, the ST40A has been designed to fully address diverse user needs, including demand for a broader range of optional devices and functions, and enhanced operability, safety and energy savings. For more information, visit www.mhi.co.jp/en.

OCTOBER 2013 59 Lucifer Furnaces Delivers Inert Atmosphere Furnace

Lucifer Furnaces, Inc. has designed and manufactured a heat treating box furnace for use with inert atmosphere for stress relief of springs under nitrogen atmosphere. Model 7GT-K36 has a working chamber area of 12”H x 12”W x 36”L and heats to 2100°F with 15 KW power. GT Models are designed with a continuously welded furnace shell for operation with a positive flow of inert atmosphere. This furnace is fabricated with 2.5” insulating firebrick and 2.5” mineral wool insulating block for superior thermal efficiency. Heating elements designed with v-grooved radiant panels and low watt density coiled elements line the sidewalls and are easy to replace. The workload is supported by a 1” thick hearth plate that protects the floor insulation and provides a flat work surface. An inlet port is mounted through the rear wall of the furnace and an adjustable outlet port with gas cock is located through the front left side. Temperature for this Series 7000 GT Inert Atmosphere Box Furnace is controlled by a Honeywell DC 2500 microprocessor time proportioning controller. With a double pivot horizontal swing door, the operator is kept safe from the door’s hot face at all times. Additional safety features include a microswitch to disengage power when the door is opened and an over temperature safety system for automatic furnace shutdown in the event of a high temperature excursion which is important for unattended furnace operation. This particular unit is complete with a flowmeter and circular chart recorder; it will be used as an addition to an existing Lucifer Furnace at a customer’s facility to reduce the residual stress from manufacturing. Stress relieving reduces the internal stress from manufacturing and increases the mechanical strength of the spring. For more information, visit www.luciferfurnaces.com.

60 gearsolutions.com CIMCOOL Solutions for Gear Grinding and Milling Needs

CIMCOOL® Fluid Technology has been the worldwide industry leader in providing innovative solutions to maximize productivity in the metalworking industry. CIMCOOL specializes in fluids for machining and grinding, stamping, drawing and forming, cleaners, and corrosion inhibitors, as well as specialty lubricants and fluid management equipment. CIMCOOL has products for companies that specialize in gear grinding and/or milling: MILPRO® 740ACF is clear, yellow metalworking oil designed for use in horizontal broaching of high temperature alloy aircraft engine parts. This chlorine free oil offers excellent water rejection, oxidative stability, rust protection, and cooling capability for a straight oil. MILPRO® 500 is a metalworking oil blended from naphthenic base stocks and is recommended for a wide range of light to medium-duty applications such as general-purpose thread grinding, tapping, gear hobbing, gear shaving, October 29-31, 2013 milling, and turning. It offers a balanced TD Convention Center Greenville, SC blend of sulfur, chlorine, and fat that produces better finishes and longer tool southteconline.com life than most competitive oils. MILPRO 500 is low misting in most applications. MILPRO® 840CF is a general purpose oil recommended for machining and grinding operations. Recommended for gun drilling, tapping, broaching, and grinding, MILPRO 840CF contains a lubrication package comprised of both a physical lubrication component and extreme pressure additives. It contains stable lubricity additives with very low depletion rates and high temperature stability. This light viscosity fluid offers cooling capability approaching water as well as provides excellent rust protection. For more information, visit www.cimcool.com generating momentum WORKFORCE | TECHNOLOGY | MANUFACTURING

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62 gearsolutions.com advertiser INDEX COMPANY NAME...... PAGE NO.

AFC Holcroft...... 57 Allen Adams Shaper Services...... 62 Apollo Broach...... 62 Ash Gear & Supply...... 23 AWEA Offshore 2013...... 47 Beavermatic Inc...... 36 Bourn & Koch...... 63 Buffalo Gear...... 19 Carbide Tool Services Inc...... 12 Chamfermatic Inc...... 18 Circle Gear & Machine...... 10 Clarke Engineering...... 39 CNC Machinery Sales Inc...... 28 DT Technologies...... 18 Encoder Products...... 28 Engineered Tools Corporation...... 32-33 Fabtech '13...... 58 Gear Solutions...... 51 Gleason Corporation...... 29 Hanik Corporation...... 63 Index Technologies...... 62 Ingersoll Cutting Tools...... 9,11,13,15 Innovative Rack & Gear...... 62 Ipsen International...... IBC KAPP Technologies...... IFC KISSsoft USA LLC...... 10 Koro Sharpening...... 62 Lawler Gear Corp...... 62 Leistritz Corp...... 37 Liebherr...... 2 Machine Tool Builders...... 16 McInnes Rolled Rings...... 14 MicroGear...... 38 Mitsubishi Heavy Industries America Inc...... BC New England Gear...... 7 Precision Gage...... 20 Process Equipment Company...... 35 Proto Manufacturing Ltd...... 34 R P Machine Enterprises Inc...... 25,52 Raycar Gear & Machine Co...... 16 Repair Parts Inc...... 38 Russell Holbrook & Henderson...... 42 South-Tec '13...... 61 STD Precision Gear...... 20 Stor-Loc...... 43 The Broach Masters Inc...... 4 The Company Corporation...... 62 TMFM LLC...... 23 Toolink Engineering Inc...... 1 500 E. Higgins Road-Ste 203 Elk Grove Village, Il 60007 PHONE 847-364-4800 FAX 847-364-4840 TTI-Tokyo Technical Instruments USA...... 46

OCTOBER 2013 63 Q&A scott richards vice president james engineering

we’re seeing many of our own customers average between 30 and 90 minutes to set a single part up for each batch. There are companies that average better, but when you get down to the details of it, it’s really difficult to nail that first setup on the very first try. Then we go into our zero setup systems, which, as the name depicts, doesn’t have any setup time. The user simply calls up the proper program, select it, hit “cycle start,” and the machine changes from one setup to another in a fraction of a second. This method is gaining a lot of popularity these days. GS: James Engineering specializes in The manual system itself is a pretty high-level solution, but we’re going a step further with deburring machines. A number of gear a machine that doesn’t require manual setup. It’s a market that people don’t fully understand manufacturers are still hand deburring their products, aren’t they? SR: I’m working with one right now—a leading forklift manufacturer, surprisingly. “The final assembly of the gears is crucial to their It’s incredibly time consuming. We’re seeing people with two or three shifts of people operation and life. They must be assembled to working five days a week just hand deburring parts. provide the optimum contact area.”

GS: Why are people holding on to this yet, but once they do, we’ll be looking back on the manual deburring systems as the “ice age.” hand-held technology? We’ve developed an automated deburring machine called the MaxSystem, taking the process SR: Well, business is a gamble, right? They beyond even manual deburring. In 2014, we’ll have a new 7-axis system. It will allow you to have a process that already works, so spending accept a gear on a stationary pedestal inside the machine—no rotary table, you can just set the money to eliminate it and jumping into a new gear down—and our 7-axis max system will actually orbit the gear, staying concentric at 90 market seems risky. degrees to the gear. Without having a rotary table, it simply runs around the part and deburs it. But these manual operators can incur a lot of money. Injury is a big issue. If an operator GS: It sounds impressive, but is it entirely functional? calls in sick, you’re really in trouble. You can’t SR: Not for every part. With certain gears—such as cluster gears—you need one grinding really place an ad for these hand-deburring wheel for each side of the gear teeth. That means four tools to debur a two-gear shaft. With specialists—it takes a lot of training to file the MaxSystem, one tool hits the top side of the first gear, moves down and hits the bottom one tooth out of 100 without nicking another. side of the gear, then repeats the process on the second gear. You can do with one tool what it If the flank on either side of the tooth is took four tools to perform in a manual system. scratched, the gear is essentially scrapped. The training on these manual deburring machines can be up to two weeks. The MaxSystem So they’re not easy to come by, and once addresses that head-on: Taking companies from being operator-dependent to no longer you have someone like that, it’s easy to operator dependent. Our vision is if Joe Blow calls in sick today, that’s fine, go pull that guy overlook the mechanized solutions. But many off the floor and tell him to select the correct part number and press start. That’s how simple of our customers want to do more with what they are. they already have. Many people ask, “Why can’t you just take a Haas and throw an abrasive in it?” That’s a great question, because the Haas is quite cheap. What happens when you put the abrasives GS: You have a range of systems. Tell in the Haas is the abrasive gets down in the way and slides, always below the perishable tool. our readers about them. That abrasive then works between the metal dust covers and gets into the rubber seal. Once it SR: Our entry-level deburring systems are impregnates that rubber seal, you have sandpaper. Our company owns a patent on putting all our manual systems. The operator manually of these important things on the roof of the machine, which gives the operator an absolutely loads and unloads the parts and simply hit clean work environment. “cycle start” on those systems. The setup times on those systems are about 10 minutes. To learn more: Unfortunately, with the manual system, it For more information on James Engineering call (303) 444-6787, takes an average of three tries to get the setup or send e-mail to [email protected]. correct. According to our own 2011 survey,

64 gearsolutions.com ®

ATLAS delivers the best in...smart solutions.

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• Intelligent controls, Carb-o-Prof®, provide you with your very own electronic metallurgist • SuperQuench with adjustable oil speed and powerful agitators • Muffle system for uniform temperature control • Safety – all ATLAS furnaces are water free for maximum safety • 30% less gas consumption • Recon® burners – single-ended recuperated tubes (SERT)

The unique HybridCarb® from Ipsen is an ultra-efficient gassing system designed to replace endothermic generators and other gassing systems. Its core strength is precision gas control. Instead of burning off excess gas, the process gas is reconditioned and reused, increasing efficiency up to 90 percent.

Other benefits of HybridCarb include: • Connects quickly and easily • Increases carburizing efficiency

• Reduces CO2 emissions by 90% • Less expensive to operate than endogenerators • Consumes significantly less gas • Lowers heat output, creating a more comfortable work environment • Powers up and down at anytime, quickly and easily

For more information, please visit www.IpsenUSA.com/ATLAS