Software Technology Steel Spur Gears

Frequencies and Properties of Compound Planetary Gears

Material Study in Steel Spur Gears

A Revelation in Advanced Software Technology

Site Safety Company Profile: Larson Forgings Tooth Tips Q&A: Scott Lynch, American Bearing Manufacturers Association

JANUARY 2008

2 GEAR SOLUTIONS • JANUARY 2008 • gearsolutionsonline.com

JANUARY 2008

VOLUME 6 NO. 58

FEATURES companyPROFILE Larson Forgings 16 By Russ Willcutt Now celebrating its 113th year in business, this fourth-generation, privately-held company is the culmination of a Swedish immigrant’s American dream. Low-Cycle Bending Fatigue of AISI 9310 Steel Spur Gears 18 By Robert F. Handschuh, Timothy L. Krantz, Bradley A. Lerch, and Christopher S. Burke This investigation—by members of the U.S. Army Research Laboratory, NASA’s Glenn Research p. 16 Center, and the QSS Group, Inc.—examines a raw material for steel spur gears. Natural Frequencies and Modal Properties of 26 Compound Planetary Gears By Robert G. Parker All vibration modes can be classified into one of three types—rotational, translational, and planet modes. In this article the author provides a detailed description. A Revelation in Advanced Software Technology 36 By George Nelson This article describes a new software package that can increase productivity, decrease programming, setup, and cycle times, and lead to greater profitability.

p. 18

DEPARTMENTS industryNEWS 8 New products, trends and developments in the gear-manufacturing industry.

siteSAFETY Terry McDonald 14 Now is the time to make sure your safety paperwork is current, so set some time aside to make an in-depth review of these important documents.

toothTIPS William Crosher 15 Epicyclic gearing is a fascinating and useful system, but it’s important to understand how these p. 26 gears act with—and on—one another. 52 Q&A with Scott Lynch, President and Secretary American Bearing Manufacturers Association

INDUSTRY RESOURCES 45 MACHINES 48 MARKETPLACE 51 ADVERTISER INDEX

Gear Solutions (ISSN 1933 - 7507) is published monthly by Media Solutions, Inc., 266D Yeager Parkway Pelham, AL. 35124. Phone (205) 380-1573 Fax (205) 380-1580 International subscription rates: $72.00 per year. Periodicals Postage Paid at Pelham AL and at additional mailing offices. Printed in the USA. POSTMASTER: Send address changes to Gear Solutions magazine, P.O. Box 1210 Pelham AL. 35124. Publications mail agreement No. 41395015 return undeliverable canadian addresses to P.O. Box 503 RPO West Beaver Creek Richmond p. 36 Hill, ON L4B4R6. Copyright®© 2006 by Media Solutions, Inc. All rights reserved. gearsolutionsonline.com • JANUARY 2008 • GEAR SOLUTIONS 5 from the EDITOR

Published by ere at the beginning of the new year we’d like to share with you some thoughts Media Solutions, Inc. penned by Valerie A. Forest, vice president of sales at Riverside Spline & Gear, P. O. Box 1987 • Pelham, AL 35124 1-800-366-2185 Inc. Titled “Who Signs Your Paycheck?” it’s a timely reminder as we all renew our 205-380-1580 fax commitment to providing excellent customer service: PUBLISHER Years ago, when I was just getting started with our company, my father asked me an David C. Cooper important question. He wanted to know who signed my paycheck. My immediate reply was, “you do,” but I was wrong. The correct answer—and one I was told to never, ever VICE PRESIDENT forget—is that it’s the customer. The importance of your relationship with your customers, whatever their sales volume, has to be of the utmost importance to you, and you Chad Morrison must work toward becoming their most-valued vendor. Everything you do is on their behalf, and you must pledge responsiveness in an open and honest manner from the national sales manager very beginning, including introducing them to and giving them the names of the people Brad Whisenant you work with. Helping them to understand your operation serves to create a sense of “partnership,” while also allowing them to feel more empowered when they work with OPERATIONS/CIRCULATION you. Look for ways to become more valuable to them as a whole. For instance, whether TERESA HALL it’s a price point or a delivery requirement, my response will most often be “let me talk with my ‘go-to’ people and see what they can do for us.” You can often detect their relief, because you are sharing the challenge they’re faced with—and we must always PRODUCTION remember that our customer also has a customer. By placing equal emphasis on every one of your customers’ concerns, you’ll be able to overcome just about anything. Work ART DIRECTOR to establish long-term relationships, because people change jobs, and you want them JEREMY ALLEN to remember you in their new position. When an old friend recommends you to a new prospect, what a compliment that is! Excellent customer service really is one of your most valuable assets, because companies come and go, but people buy from people— Graphic Designer and that will never change. MICHELE HALL HOur dedication to excellent customer service involves providing great content, as EDITORIAL you’ll find in this issue of the magazine, which includes “Natural Frequencies and Modal Properties of Compound Planetary Gears” by Robert G. Parker, a professor in EDITOR the Department of Mechanical Engineering at The Ohio State University—the first in a RUSS WILLCUTT three-part educational series by various authorities devoted to noise analysis. We’re also delighted to offer “Low-Cycle Bending Fatigue of AISI 9310 Steel Spur Gears,” written Contributing Writers by Robert F. Handschuh and Timothy L. Krantz, who are with the U.S. Army Research Christopher S. Burke Laboratory; Bradley A. Lerch, with NASA’s Glenn Research Center; and Christopher S. William P. Crosher Burke, who is with the QSS Group, Inc. In addition, we’d like to welcome George Nelson Robert F. Handschuh of Bryant Grinder to our pages. Larson Forgings is our company profile, and Scott Timothy L. Krantz Lynch—president of the American Bearing Manufacturers Association—is this month’s Bradley A. Lerch Q&A subject. Bill Crosher provides another excellent installment of his “Tooth Tips” col- Terry McDonald umn, and Terry McDonald does his usual great job of bringing important issues to the George Nelson forefront in “Site Safety.” Robert G. Parker We hope you’ll enjoy this issue of Gear Solutions, and that you’ll feel free to contact us whenever you have a story idea or press release. All best:

No part of this publication may be reproduced or transmitted in any form Russ Willcutt, editor or by any means, electronic or mechanical, including photocopy, record- ing, or any information storage-and-retrieval system without permission Gear Solutions magazine in writing from the publisher. The views expressed by those not on the [email protected] staff on Gear Solutions magazine, or who are not specifically employed (800) 366-2185 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 submissions are welcome, and can be submitted to [email protected]. 6 GEAR SOLUTIONS • JANUARY 2008 • gearsolutionsonline.com FULL SERVICE Gear

rebuilding, to servicing, to retrofitting, to We do it all, from parts for all models. designing custom machines. We also stock We are your one-stop source with more than 150 shapers in stock. Our machines are equipped with one- through six-axis controls. We have a dedicated professional staff with over a hundred years of combined experience in shaper needs and performance. We can handle your CAD/CAM through schematics to operational procedures. We have on staff electrical engineers who design allWe our custom software and we do all machined parts in house. are truly your one-stop shop for everything in shapers. We own what we sell and we stand proudly behind everything we do.

newenglandgear.com 343 John Downey Drive | P.O. Box 1120 | New Britain, CT 06051 | Phone: 860-223-7778 | Fax: 860-223-7776 New Products, Trends and Developments in the Gear-Manufacturing Industry

Media Solutions Announces Promotion Gear Solutions Congratulates Winners Media Solutions, Inc., is pleased to announce the promotion of of GEAR EXPO Raffle Russ Willcutt to executive editor. Formerly managing editor of Hundreds of GEAR EXPO 2007 attendees signed up for a chance Gear Solutions magazine and Gear Solutions China, he will now to win Nike golf clubs in Detroit last October. The winners of a serve as editor of those publications while overseeing all edito- Nike Sumo driver were Doug Fellman of Engineered Abrasives; rial aspects of the company’s growing project base. Ken Keller of Engineered Tools Corporation; and Thomas Beach “We’ve been a team since we began planning the first issue of Peening Technologies. Todd Sakai of YMT of Gear Solutions, which was launched back in 2003, and we’re delighted to cement our relationship in this way as the company continues to develop exciting new publications in a wide variety of markets,” says David C. Cooper, president of Media Solutions, Inc. A graduate of the University of Alabama at Birmingham (UAB), Willcutt studied English, journalism, and art history, working in the university’s student publications group throughout his college years and winning a “Silver Crown Award” for copy editing from the prestigious Columbia Scholastic Press Association. He was then hired by his alma mater’s publishing division—creating and editing publications for many of UAB’s 12 Schools, including Engineering, Business, Education, Medicine, Dentistry, and Health Professions—while also serving as assistant editor of its flagship publication, UAB Magazine. He then joined Thomas Beach the HealthSouth Corporation as group managing editor of its publishing department. He has also worked as managing editor of Executive Traveler magazine. Since joining Ken Keller Doug Fellman Media Solutions he has overseen the editorial development and production of Gear Solutions, Gear Solutions China, and Vision—a custom publication for the UAB Department of Ophthalmology. He has also assisted in marketing activities for the company, including developing materials for its client’s ads and Web sites. Willcutt is also editor of Venture magazine, a high-end monthly publication devoted to accessible travel that will be launched by Media Solutions in April of this year. “What we have here is a group of people whose professional strengths complement one another,” he says. “We enjoy what we do, and working with each other, which I think is apparent in our interactions with our clients and in everything that we produce.” To learn more go to [www.gearsolutionsonline.com] or [www. gearsolutionsglobal.com]. Also visit [www.talkgears.com] and Todd Sakai [www.mediasolutionsincorporated.com]. Information on Venture magazine is available at [www.venturetrav.com].

TO SUBMIT: Companies wishing to submit materials for inclusion in Industry News should contact Editor Russ Willcutt at [email protected]. Releases accompanied by color images will be given first consideration.

8 GEAR SOLUTIONS • JANUARY 2008 • gearsolutionsonline.com

International won a Nike putter. winners, and I hope these clubs will help CORE Filters Available on According to David C. Cooper—president improve their game!” Philadelphia Gear Web of Media Solutions, Inc., which produces Media Solutions has attended every Site Gear Solutions magazine—“This is the GEAR EXPO held since Gear Solutions Officials of Philadelphia Gear Corporation second year we’ve raffled off golf clubs was launched in 2003. To learn more visit have announced the online availability of at GEAR EXPO, and we see it as a way our Web site at [www.gearsolutionson- the company’s proprietary Continuous Oil of thanking people for stopping by our line.com], where you can also access our Rescue Equipment, or CORE. Launched booth to say hello,” he says. “It always entire searchable article database and as an alternative to traditional barrier fil- draws a large crowd, and it’s a lot of fun download materials for future reference. tration techniques, the CORE is available for everybody. I’d like to congratulate the in two models and filters metallic par- ticles as small as one micron (one-mil- lionth of a meter). Unique to Philadelphia Gear, these filters are now available for direct purchase on its Web site, which is listed below. THE SEVENTH LARGEST USED MACHINERY WAREHOUSE IN THE WORLD “The simplicity of the CORE filter sale offered Philadelphia Gear a unique oppor- tunity to do business with our customers in a whole new way, via the Internet,” says CEO Carl Rapp. “CORE was a perfect fit for an online ordering system because its price point allows customers to purchase the filter out of their discretionary operating maintenance budgets.” The durability of each CORE filter is matched only by its compactness. Both CORE versions hold significantly more contaminant than a conventional filter because of their three-dimensional storage capacity. This increased capacity We have a variety of flexible services also allows for longer periods of opera- to fit your needs tion without service. Inside the cast aluminum housing is an assembly of five magnets, each surrounded by a set of Consulting steel flux plates. A series of “collection C ustomized marketing plans 150,000 square foot designed to meet your company’s zones” are machined into the plates such unique business needs. used machinery warehouse that oil flow is never restricted, even as APPRAISALS • Take it to the bank: Accurate, all at one location debris begins to build up inside the filter. expert equipment appraisals 2,500 machines in stock These plates create magnetic fields that from AMEA-certified appraisers. • strip ferrous metal contaminants out of AUCTIONS Over $44 million gross sales in the two 50 ton p&h cranes the lubricant, while keeping the pressure last three years. • flow at its maximum, constant rate and LIQUIDATIONS railroad siding preventing debris from washing off back The right buyers...the right prices. into the lubricant; a significant advan- brokerage A sensible, commission-based sales tage over other methods of filtration. option. For more information about CORE and consignment its benefits, or to purchase a CORE A full-service partner you can depend on. filter, go to [www.philagear.com/core. shtm]. Also call (800) 766-5120 or visit storage Secure storage at a reasonable the company’s main Web site at [www. price. philagear.com]. Niagara Gear Announces Plant Expansion Niagara Gear Corporation has announced 10601 Glendale Road • Cincinnati, Ohio 45215 an 8,000 square-foot expansion that Phone (513) 771-1952 • Fax (513) 771-5120 • Email: [email protected] features an upgraded Gear Cutting www.mohawkmachinery.com Center, new manufacturing-engineering offices, and an expanded Gear Grinding

10 GEAR SOLUTIONS • JANUARY 2008 • gearsolutionsonline.com Department. The recently completed an offset drive shaft that makes it ideal from 24-85 RPM with gear ratios from expansion brings Niagara Gear’s total for use in applications where space is 20:1 to 72:1 and up to 1,000 lb-in. of plant size to over 30,000 square feet. limited. The unique design of this gear- torque. Hollow shaft versions of the type The expanded facility allows Niagara head allows it to be face-mounted from 3RD and HG gearmotors are available via Gear to install a time-efficient inven- either side. It produces output from 16 Bodine Electric’s special-order program. tory system aimed at improving workflow. to 63 RPM, with gear ratios of 27:1 to The Bodine Electric Pacesetter, invert- The expanded manufacturing space also 108:1, and up to 1,000 lb-in. continuous er duty AC motors and gearmotors are allows for room for growth, including the torque. Almost every component of the rated from 1/25 - 3/4 HP, 230 VAC, ability to add more machinery. type GC was designed for higher-than- 60 Hz, 3-phase. All feature Bodine’s “The expansion opens the door for usual performance. It produces output Quintsulation™ 5-stage insulation sys- future capital equipment purchases because we now have the floor space to do it,” says Vice President and General Manager Robert Barden. “This signifies positive growth for Niagara Gear.” In keeping with this philosophy, the company has recently purchased a new CNC cylindrical grinding machine. This state of the art technology can offer solutions to satisfy a variety of needs; everything from applications in the tool room to high precision, automated production environments. Niagara Gear Corporation is an established, world-class manufacturer of precision ground spur, helical, and pump gears, utilizing the latest in gear grinding technology. Since 1974, Niagara Gear has offered complete capabilities to meet the most demanding, close-tolerance requirements in industry segments such as automotive, locomotive, aerospace, pumps, and missile systems. To learn more call (800) 447-2392, send e-mail to [email protected], or go online to [www.niagaragear.com]. Bodine Expands Inverter Duty Gearmotor Selection Bodine Electric Company announces that it has expanded the Pacesetter™ family of AC inverter duty, three-phase gearmotors and motors. Inverter duty gearmotors are now available with Bodine’s newest gearheads: the types 3RD, HG, and CG. Typical applications for these gearmotors include conveyor systems, food processing equipment, medical equipment, and factory automation. The new gearheads each feature unique characteristics that fill out the Pacesetter product line. The type 3RD is a double- reduction gearhead designed for applications that require very slow rotation and very high torque. It produces output from 0.5 up to 8.5 RPM, with gear ratios from 200:1 to 3,600:1, allowing a relatively small motor to product up to 148 lb-in. of torque. The type HG gearmotor features

gearsolutionsonline.com • JANUARY 2008 • GEAR SOLUTIONS 11 ing for Homestead, Pennsylvania-based ASKO Inc., a producer of specialty wear-resistant tooling for the metal producing, processing, and recycling industries. Re-elected to serve three-year terms on the board were Tom Connell, CEO with Main Steel Polishing Co., Tinton Falls, N.J., and Carlos Rodriguez, general director of ACERO PRIME, San Luis Potosi, Mexico. Vivek Kumar Gupta, managing director for Texas ProFab Corporation, Carrollton, Texas, was appointed to serve a one-year term as a young professional (YP) associate director to the board. The YP program was initiated to provide FMA board members with perspectives and ideas from young executives in the industry. Additionally, FMA Communications Inc. (FMAC)—the publishing arm of the association—elected Rick Schwer, vice president and group publisher for Scranton Gillette Communications, which is based in Arlington Heights, Illinois—to its board of directors. Schwer will serve a one-year term on the 12-member board. Based in Rockford, Illinois, the FMA is a professional organization with more than 2,000 members working together to improve the metal forming and fabricating industry. Founded in 1970, FMA brings metal fabricators and fabricating equipment manufacturers together through technology councils, education- tem, which meets NEMA MG 1-1993, Section IV, Part 31. This al programs, networking events, and the FABTECH International insulation protects the motor from potential spikes or corona & AWS Welding Show. FMA also has a technology affiliate, the damage caused by the inverter. Pacesetter gearmotors are UL Tube & Pipe Association, International (TPA), which focuses on recognized for construction, CSA certified, and in compliance the unique needs of companies engaged in tube and pipe pro- with the Low Voltage Directive “CE.” Most Bodine 34R and 42R ducing and fabricating. frame inverter duty gearmotors are now available by special To learn more contact Patricia Lee at (815) 227-8286, or send order with optional 230/460 VAC, 60 Hz windings. As a true e-mail to [email protected]. Visit online at [www.fmanet.org]. system-solution provider, Bodine Electric Company also offers a range of AC inverters (Variable Frequency Drives), both as Street Crane Announces New chassis type (IP-20) and enclosed (NEMA-1 and -4). Appointment Founded in 1905, Bodine Electric Company is a family-owned One of the most respected people in the North American crane business that offers over 1,000 standard products and thou- industry, Dick Davidson. is to spearhead Street Crane Company’s sands of custom designed fractional horsepower (less than 1 sales drive in the United States and Canada. The largest inde- HP) electric motors, gearmotors, and motion controls (AC induc- pendent crane maker in the U.K., Street has invested heavily tion, brushless DC, and permanent magnet DC). Products are in developing a new generation of advanced hoists to set new available via an extensive distributor network or sold directly standards in flexibility, performance, and competitiveness. to OEMs. Known for their reliability, long life, and competitive “In my new role I will be responsible for introducing indepen- prices, Bodine products are found in many demanding indus- dent regional crane builders to Street’s advanced hoist technol- trial and commercial applications such as medical devices, ogy, and I also hope to win over many end users,” Davidson labeling equipment, printing presses, photocopier, scientific says. “Street has had a presence as a hoist supplier in North and laboratory equipment, and factory automation. Bodine America for only a little time but has gained a reputation for is headquartered in Chicago, Illinois, with manufacturing and hoists that are innovative and soundly engineered. I have been assembly operations in Peosta, Iowa. For more information go able to see the new generation of hoists that Street has devel- to [www.bodine-electric.com]. oped and think that North American manufacturers will appre- ciate not just their design and build quality, but exceptional FMA Elects New Chairman, Directors competitiveness.” Steve Heim, president of Brenco Industries, British Columbia, Davidson has spent his entire professional career in the Canada, was elected to a one-year term as board chairman industrial crane industry. Since graduation from Mississippi of the Fabricators & Manufacturers Association, International State University, with a degree in math, he has worked for major (FMA), at the group’s recent annual meeting. Also, R. Bruce manufacturers such as Eaton-Yale Hoist, R&M, and DeShazo. Benedict, Edwin Herbert Stanley, and Al Zelt were elected to the A past president of the Crane Manufacturers Association of organization’s board of directors and will serve three-year terms America, he is widely known throughout the industry. The on the 15-member board. Benedict is president of Production appointment is part of a worldwide expansion for Street Crane, Tube Cutting, Inc., of Dayton, Ohio; Stanley is vice president of which is aiming to substantially increase its hoist and compo- operations for The Gas House, a metal fabrication shop based nent sales business. For the past three years the company has in Fort Payne, Alabama; and Zelt is director of sales and market- been developing a new generation of hoists for volume produc-

12 GEAR SOLUTIONS • JANUARY 2008 • gearsolutionsonline.com tion and worldwide sale. Using 3D modelling techniques, finite element analysis, critical vibration tests, and accel- erated life testing, the company has developed a family of robust modular based hoists. These meet or surpass U.S. and international standards and have the adaptability to meet the specific needs of many users. More information is available by contacting Davidson at (704) 998-9484 or sending e-mail to dick.davidson@ streetcrane.co.uk. Go online to [www.streetcrane.co.uk]. Encore Group Joins Ranks of Dura- Bar Distributors Dura-Bar, the only North American producer of continuous cast iron bar stock, announces that it has expanded its Western U.S. and Canadian distribution network by adding the Encore Group Limited of Edmonton, Alberta. The Encore Group—which consists of Encore Metals and Team Tube in Canada—is a subsidiary of the Reliance Steel & Aluminum Company. “We’re pleased to welcome The Encore Group to our distribution network,” says Frank Abruzzo, Dura-Bar’s vice president of sales and marketing. “Encore’s 17 locations and processing capabilities will bene.t Dura-Bar users in those areas.” As a Dura-Bar distributor, The Encore Group will be able to supply the full range of Dura-Bar continuous cast gray and ductile iron bar stock in a wide variety of sizes and shapes. In addition to Dura-Bar, Encore specializes in the processing and distribution of carbon and alloy bar stock and tubes, as well as stainless steel and carbon plate. Their processing capabilities include bar sawing, trepan- ning, and plate sawing. Encore Metals already has experience with Dura-Bar and had been a distributor in the 20 years prior to 2004, when it was part of Corus Metals. For more information go to [www.dura-bar.com]. Advanced Heat Treat Opens New Facility Advanced Heat Treat Corp. is growing to better service its customer base. In order to meet customer needs, AHT has expanded its resources by opening a fourth full service UltraGlow® facility in Cullman, Alabama. The new facility will include one of the world’s largest vacuum ion nitriding vessels, with a 60,000 pound capacity and an enormous work zone. This facility has the flexibility to service large tooling/stamping dies and high-volume production components, as well as prototype and developmental processing. AHT’s UltraGlow ion nitriding process is a proven case- hardening method designed to improve the part’s performance, wear resistance, strength, and endurance. It’s a high-tech surface treatment developed for engineered steel, titanium, and cast-iron parts. AHT is committed to serving each of its client’s distinct needs, and it is confident its facilities expansion will help better serve its customer base. “We continue to focus on building solid relationships with each of our customers,” says Gary Sharp, president and CEO, “and we’re looking

Continued On Pg 42 >

gearsolutionsonline.com • JANUARY 2008 • GEAR SOLUTIONS 13 terryMcDONALD siteSAFETY Member of the ANSI Subcommittee on Gear Safety

Now is the time to make sure your safety paperwork is current and readily available, so set some time aside to make an in-depth review of these important documents.

t is now 2008—do you know where the hearing of the upcoming generation. your Safety Manual is? Is your “Often the first sign However, I also know that the years I spent Emergency Preparedness Plan up to in the shop environment as a young man date? The beginning of a new year is definitely affected my ability to hear. Even always the perfect time to review the of machine failure is then, although the newer, better hearing status of your plans and manuals. As we protection was not available then, I did not have discussed in the past, your Safety the sound it makes, and consider the consequences. I could have Manual and Emergency Preparedness taken more precautions than I did, and Plan should be ever-evolving documents. if our employees can’t now I regret it. I hope that all the employ- Each change in your business—whether ers reading this will make hearing tests in personnel, equipment, operations, or in available for their employees and require the facility itself—requires updating both hear it the results can the use of proper hearing protection. of these crucial documents. While you’re None of us want a generation of “hard of at it, you should also review the status be huge in terms of hearing” personnel, after all. Remember, of your Material Safety Data Sheets. It is even the newest equipment is subject to very important that you keep this file up failures, and often the first sign of these to date. It requires discarding the sheets downtime and cost of failures are the sounds the machines for materials you are no longer using, make. If our employees can’t hear these as well as obtaining the latest versions repair.” sounds, the results can be huge in terms of the sheets that you need. Of course, One of the topics in this month’s issue of downtime and cost of repair. The cost of everyone realizes that every employee in of the magazine is “noise analysis,” and training and proper ear protection is a very your company must have readily available while this is an ever-increasing concern small expense when compared to the lost access to your MSDS records, but are in the gear industry, noise is also a huge hours and repair costs. Always remember you sure that all the copies have been safety concern. We have discussed in that the large amounts of money invested updated? Even if you are sure that your previous columns the necessity to provide in our equipment, and the time and money master copies are the latest and great- required safety gear to your employees. that is invested in our employees—who est, are you sure that all other copies are After proper eye protection, I feel that ear are our single-most important asset—is theI same? In general, what I am saying is (hearing) protection is the most important small when compared to the equipment. that at the first of each year you should thing we can emphasize. I know that many The only way the investment in equipment set aside some time to review all the of the newer generation coming into the pays off is through the work of the employ- records, manuals, and plans pertaining to industry feels that they are immune to ees, so it only makes financial sense to the safety and continued operation of your hearing damage and refuse the use of invest in their well being by providing the company. You will find that if you actually hearing protection that we, as employers, best safety programs that we possibly schedule this review, the rest of your year provide. I also know that as a member of can. should have fewer surprises, and you will the “older” generation I have heard how I hope that each and every one of you actually be better prepared for anything loud the music is that younger people had a safe, happy, and joyous holiday that may occur. listen to today, and I am concerned about season!

About the author: With more than 30 years of experience in the gear industry, Terry McDonald is partner and manager of Repair Parts, Inc., and a current member and past-chairman of the American National Standards Institute B11.11 Subcommittee on Safety Requirements for Construction, Care, and Use of Gear Cutting Equipment. McDonald writes this monthly column specifically for Gear Solutions magazine, and he can be reached at (815) 968-4499 or [email protected]. The company’s Web site is [www.repair-parts-inc.com].

14 GEAR SOLUTIONS • JANUARY 2008 • gearsolutionsonline.com williamCrosher Author, engineer, and former director of the toothTIPS National Conference on Power Transmission

Epicyclic gearing is a fascinating and useful system, but it’s important to understand how these gears act with—and on—one another. Read on to learn more.

dictionary description of epicyclic gear- and annulus. Epicyclics have an important ing is as follows: “A system of gears “The main reasons for the advantage over other drives in the distribution in which one or more gears travel of power within the unit. The power from input around the inside or the outside of to output is absorbed by as many meshes another gear whose axis is fixed.” increased use of epicyclic as there are planets. With three planets, for Epicyclic gearing can have a fixed or rotating example, the meshing forces are reduced by annulus, while a planetary unit always has a drives are that they use one third. The correspondingly higher rotary fixed annulus. Such drives have been used movement per unit of time is insignificant for for a long time, from the Watts steam engine gears with an adequate fatigue rating. This in 1785 to Henry Ford’s patent in 1911. The less material, which also applies to the alternating direction of the use of such drives is becoming more and dedendum bending strain. The lower periph- more important, as they are to be found in an means less weight and eral speeds reduces the dynamic stress and increasing number of applications. Powers in audibility. excess of 45,000 hp and speeds > 17,000 The construction of such units is not easy. rpm are now being attained. Slow speed steel volume; critical issues Maintaining the manufacturing tolerances is mill applications have units >25 million ins/lbs critical, as well as understanding the counter of torque. On the other end of the scale we find action of elastic bending and twisting. The their use in servo-mechanisms. The main rea- on such applications as main tolerances are for pitch, tooth thickness, sons for their increased use are that they use tooth profile, tooth flank, parallelism, and cen- less material, making a savings in our natural wind turbines.” ter distance. Back-to-back tests have shown resources. Less material means less weight that roller bearing supported units can be pro- and volume; critical issues on such applica- from the planets. Should one of these carry vided with guaranteed efficiencies in excess tions as wind turbines, where the drives are more than its share of the load, the rings—i.e. of 99.5 percent. Hydro-turbines, for example, located in a nacelle far above the ground. roller race—will deflect sufficiently to relieve insist on guaranteed efficiencies. Load shar- There are three basic types: planetary some of the extra load. The internal gear ing among the planets is most important. All with fixed annulus, input and output rotate rings are held by a system of tooth couplings planets must have the same tooth thickness in same direction, single stage ratios 3;1 to that allows them to deflect and follow the and negligible eccentricity of the annulus with A12:1; star gear with a fixed carrier assembly, movement of the planet carriers. Other load respect to the axis. The sun gear shaft and input and output rotate in opposite directions, sharing methods for high-quality gears include the planet wheels must all run concentrically ratios 2;1 to 11:1; and solar gear, fixed sun increased tolerances for the carrier gear error free. The manufacturer has to check the wheel, input and output in same direction, locating components, matching the planet concentricity after assembly. One way is to ratios 1;1 to 1.7:1. The high-power, state of gear tooth thicknesses, radial float for one check for any deviations in backlash as the the art units are for the most part based on or more components, elastic deformation of unit is rotated. The measurements are taken the Stoeckicht design. The design is based ring/and or sun gear, reduced tooth stiffness, after several rotations at 120º increments. on a floating sun wheel, internal ring gear, and and elastic deformation of planet gear shafts When the unit is run, errors will result in a planet spindles. The sun wheel supported and planet carrier. The selection is often pulsating sound. Excessive play in the planet only by its teeth meshes with the planet determined by direction of rotation, the power, carrier bearings and tooth profile errors are all wheels that can move to a position which, and speeds. Planetary for most applications items that contribute to unequal loading. The under a static equalibration, yields equal load is the first choice because it usually provides tooth flexibility in relation to the tooth stiff- to all the meshes. Allowing flexible internal the smallest envelope. The basic ratio is the ness is not of itself an assurance that there gears that can deflect under the tooth loads ratio of the number of teeth in the sun wheel will be an equal transmission of power.

About the author: William P. Crosher is former director of the National Conference on Power Transmission, as well as former chairman of the AGMA’s Marketing Council and Enclosed Drive Committee. He was resident engineer-North America for Thyssen Gear Works, and later at Flender Graffenstaden. He is author of the book Design and Application of the Worm Gear.

gearsolutionsonline.com • JANUARY 2008 • GEAR SOLUTIONS 15 companyPROFILE

Larson Forgings

16 GEAR SOLUTIONS • JANUARY 2008 • gearsolutionsonline.com three, for a total of 250,000 square feet of office and manufactur- Now celebrating its 113th ing space—and began to define its market presence. This was during the oil-field boom of the early eighties, which brought in a great year in business, this fourth- deal of work, and Larson Forgings also began making its mark in the aerospace industry, to the extent that it now represents the company’s primary focus. “We also do a lot of valve work, whether generation, privately-held that be for the oil/gas or petrochemical industries,” Larsons says, “and we also forge parts for the nuclear energy and power genera- company is the culmination tion industries.” This variety provides one of his favorite aspects of his job. “As a purchasing agent I get to visit the mills where our materials are of a Swedish immigrant’s made,” Larson explains, “and then in my sales role I get to sell it to our customers and then visit their plants to learn about how their American dream. products are manufactured. It’s fascinating to get this ‘inside view’ of how things are made, and it really keeps me excited about what By Russ Willcutt I do.” In recent years these site visits have required traveling longer n the late 1800s a blacksmith left Sweden and traveled to distances, since the company now ships its products and materials America, settling in Chicago, where he planned to build a new all around the world. “We’re now doing business with companies in life. He set up shop downtown, beside the Chicago River, and China, Europe, Asia, Singapore, Australia… it’s amazing how many immediately picked up work making horseshoes and forging countries we serve these days,” Larson says. “And that’s definitely gears and replacement parts for ships plying the Great Lakes. something we’ll continue to pursue.” IHis family’s size kept pace with the growth of his business—he As for the company’s capabilities, it works with a wide variety had 11 children, five of them boys—and he decided to launch his of materials, the larger portion being high-temperature and nick- company as Charles E. Larson & Sons, Inc., in 1895, which is now el-based grades, as well as stainless, carbon, and alloy. “We do known familiarly as Larson Forgings. shapes, bars, blocks, and discs for all the markets we serve, but “Every one of those sons joined the company, and it remains we mainly do rolled rings,” he says. “We were a partner with U.S. a privately-held, family-owned business to this day,” according to Steel after World War II in developing ‘stainless W,’ which was the Glenn Larson, who is vice president. “My brother Don is president precursor for all the precipitation hardened stainless steels, and we of the company, and we’re members of the fourth generation of also work with aluminum, titanium—you name it, we forge it.” Larsons who are carrying on Charles’ legacy.” Larson Forgings has all the necessary certifications in place, in- In the 1930s the company relocated from its riverside site to cluding ISO 9001:2000 and AS 9100, as well as NADCAP certifi- another one bordering a rail line, which delivered the forge’s stock cation for its heat-treating activities. Despite the wide range of its and also an industrial hammer that records show cost a whopping capabilities and customer base—and the fact that it now employs $1,500—which was a pretty penny, at the time. The company con- some 85 people—the company still sees itself as a hands-on, can- tinued its growth trajectory over the years, and Don Larson joined do operation where everyone pitches in wherever they’re needed. it straight out of college, after earning his degree in engineering. “This really is a family, and in many senses of the word,” Larson Glenn Larson chose a different path, majoring in business and po- says. “We have fathers and sons who are working here together, litical science at DePauw University, and then working for nine years and if a light bulb needs changing, you change the light bulb. We in retail management. Then, in 1979, he decided that it was time still think of ourselves as a small company, so you do what needs for him to join the family business as well. to be done, whatever your job title may be. And that’s certainly the “This was when retail stores were just starting to stay open seven case for all of the Larsons who are working here, because when days a week, which meant additional hours for me, and the com- your name’s on the door, you take a special interest in what’s hap- pany had just purchased a second building beside its main struc- pening inside.” ture, so when they told me they needed help I felt that it would be a This is especially true when it comes to customer service, on good idea for me to fill that position myself,” he says. “Besides, the which Larson Forgings places a premium. “This is one of the few work I’d been doing was the perfect training ground for what I’m do- places I know of where a customer might end up talking to the ing now, which involves managing our sales activities and handling president of the company when they call,” Larson laughs, “because about half of our purchasing, along with my cousin Keith.” when the phone rings, you answer it, no matter who you are. And Business was good, so the company bought a 1,000-ton press I think that’s one of the many things that makes this company which was installed in the newly acquired building—there are now special.”

For more information: Call (773) 772-9700, send e-mail to [email protected], or visit online at [www.larsonforge.com].

gearsolutionsonline.com • JANUARY 2008 • GEAR SOLUTIONS 17 18 GEAR SOLUTIONS • JANUARY 2008 • gearsolutionsonline.com This investigation—by members of the

U.S. Army Research Laboratory, NASA’s

Glenn Research Center, and the QSS

Group, Inc.—examines a raw material

for steel spur gears.

By Robert F. Handschuh, Timothy L. Krantz, Bradley A. Lerch, and Christopher S. Burke

An investigation of the low-cycle bending fatigue of spur gears made careful analysis.” In the AGMA standard, the stress-life relationship from AISI 9310 gear steel was completed. Tests were conducted for the cycle regime comprising 100 to 10,000 cycles is depicted using the single-tooth bending method to achieve crack initiation and as a single value for the allowed bending stress. Thus, the problem Apropagation. Tests were conducted on spur gears in a fatigue test is how to properly account for severe loads to estimate the fatigue machine using a dedicated gear test fixture. Test loads were applied lives of gear teeth. The standard’s analysis techniques calculate a at the highest point of single tooth contact. Gear bending stresses for life at a given stress for 99 percent reliability at the component level. a given testing load were calculated using a linear-elastic finite ele- This means that a large population of components designed using ment model. Test data were accumulated from 1/4 cycle to several the allowable stress values should experience crack initiation at a thousand cycles depending on the test stress level. The relationship rate no greater than 1 per 100 for the given cycle count. To provide of stress and cycles for crack initiation was found to be semi-loga- a credible estimate of fatigue life at 99 percent reliability, extensive rithmic. The relationship of stress and cycles for crack propagation experimental data is required to establish the load-life relationship in was found to be linear. For the range of loads investigated, the crack the low-cycle fatigue (<10,000) regime. propagation phase is related to the level of load being applied. Very Published experimental data for the fatigue of case carburized high loads have comparable crack initiation and propagation times gears for loads sufficient to fail the gear in the range of hundreds to whereas lower loads can have a much smaller number of cycles for several thousand cycles is sparse (refs. 2 and 3). At gear loads that crack propagation cycles as compared to crack initiation. can fail a gear within several thousand cycles a certain degree of nonlinear material response is taking place since the bending stress calculated at the fillet radius-root region of the tooth exceeds the mate- Introduction rial yield strength. The tensile yield strength of the carburized case In certain space applications of gears, the level of loading applied to layer is estimated to be 295 ksi (2.03 GPa) (ref. 4). Therefore, linear- the gear mesh members can be large enough to cause a great deal of elastic-based gear stress analyses should be considered as providing the gear’s life to be used in a short number of cycles. The American stress-based indices of loading intensity (pseudostress) rather than Gear Manufacturers Association (AGMA) standard for evaluating as representing the true stress condition of the material. fatigue of gears (ref. 1) states: “The use of this standard at bending In certain space mechanism applications a limited number of stress levels above those permissible for 10,000 cycles requires extremely high loads can be imparted to the gear system com-

gearsolutionsonline.com • JANUARY 2008 • GEAR SOLUTIONS 19 Figure 1: Schematic of test fixture for bend- Figure 2: Test ing fatigue of spur gear modified and gears. Note: Test tooth installed in text is loaded at the point fixture. of highest single tooth contact.

Table 1: Nomi- Element Wt% nal Chemical Composition Carbon 0.10 of AISI 9310 Nickel 3.22 Figure 3: Test fix- Gear Material Chromium 1.21 ture in fatigue test machine. Molybdenum 0.12 Copper 0.13 Manganese 0.63 Silicon 0.27 Sulfur 0.005 Phosphorous 0.005 Iron Balance TABLE 2.—HEAT TREATMENT FOR AISI 9310 GEARS Step Process Temperature Time, hr melted material. Post-test metallographic inspections of test gears K °F revealed levels of inclusions higher than would be anticipated for 1 Preheat in air ------such material. Inspections of failed surfaces show that fatigue was a surface-initiated phenomenon, and therefore it was judged that the 2 Carburize 1,172 1,650 8 higher than expected level of inclusions did not degrade the fatigue 3 Air cool to room ------performance of the gear teeth. temperature The dimensions for the test gears are given in table 3. The gear 4 Copper plate all ------pitch diameter was 3.5 in. and the tooth form was a 20° pressure over angle involute profile modified to provide a tip relief of 0.0005 in. 5 Reheat 922 1,200 2.5 starting at the highest point of single tooth contact. The gears have 6 Air cool to room ------zero lead crowning but do have a nominal 0.0005 in. radius edge temperature break at the tips and sides of the teeth. The gear tooth surface fin- 7 Austentize 1,117 1,550 2.5 ish after final grinding was specified as a maximum of 16 min. rms. Tolerances for the gear geometries were specified to meet AGMA 8 Oil quench ------(American Gear Manufacturers Association) quality level class 11. 9 Subzero cool 180 –120 3.5 Gears manufactured to these specifications have been used at the 10 Double temper 450 350 2 each Army Research Laboratory and the NASA Glenn Research Center for 11 Finish grind ------gear experiments including contact fatigue (refs. 4 to 6), gear wear 12 Stress relieve 450 350 2 (ref. 7), loss-of-lubricant performance (ref. 8), gear crack propagation paths (ref. 9), and health and usage monitoring (ref. 10). Table 2: Heat Treatment for AISO 9310 Gear Material ponents. The effect of these high loads on the life of the mechanism needed to be answered. Therefore the objective of this work was to Test Fixture assess experimentally the low-cycle bending fatigue of spur gears The fatigue test machine used for this investigation was a servo- made from case-carburized AISI 9310 steel. Tests were conducted hydraulic test system with 20,000 lb. load capacity. With the excep- using a commercially available fatigue test machine with a special tion of the gear test assembly, the test system was in standard fixture specifically designed to load the test gear tooth at the highest configuration for fatigue testing smooth shank, cylindrical specimens. point of single tooth contact. The load mechanism features an alignment fixture that can be used for closely controlled positional and angular adjustments. The 20,000 lb load cell is positioned between the alignment fixture and the top Test Specimens and Material grip. The output from the load cell can be used for control purposes The test gears used for this work were manufactured from AISI 9310 and/or simply monitored as required by the test program. The gear steel. The nominal chemical composition of the AISI 9310 material test assembly is mounted in the load frame using a support arm is given in table 1. The gears were case carburized and heat treated which is attached to the two-post load frame. The bottom grip is according to table 2. The nominal properties of the carburized gears attached to the actuator which serves to power the system using have a case hardness of Rockwell C60, a case depth of 0.038 in., 3000 psi oil supplied by a central hydraulic system. An AC type linear and a core hardness of Rockwell C38. The manufacturing specifica- variable differential transformer (LVDT) is attached to the base of the tion for the test gears required use of consumable-electrode vacuum- load frame and used to measure actuator displacement or stroke. As in the case of load, stroke output can be used for test system

20 GEAR SOLUTIONS • JANUARY 2008 • gearsolutionsonline.com control and/or simply monitored as required teeth had been achieved (fig. 4). The contact gear was positioned to provide load on the by programmatic needs. pattern procedure was followed in all tests test tooth at the theoretical highest point of Key details of the gear test assembly are with excellent results, and the contact pat- single tooth contact for the case of the test shown in figures 1 to 3. The gear test speci- tern data were recorded photographically and gear mating with an identical gear at the men is positioned on a shaft which is a press stored for quality assurance purposes. standard center distance. The load is cycled fit in the fixture’s casing. The test assembly from a small, minimum load to the maximum was designed to conduct tests on gear teeth load desired for the given fatigue test. The in sets of three. This approach was adopted Test Operation load range was maintained a constant value in part to provide the necessary clearance for The single tooth bending tests of this study throughout the test. Loading was cycled at the two load rods. To permit access to the were conducted using unidirectional load- 0.5 Hz using a sinusoidal waveform. A typical gear tooth to be tested several teeth nearby ing. Testing was done in load control. The load waveform is shown in figure 5. needed to be removed. Teeth were removed using the Electrode Discharge Machining (EDM) process. The upper load rod contacts the reaction gear tooth near the root of the tooth. In contrast, the lower load rod contacts the test gear tooth at the highest point of single tooth contact. Adopting this approach, highest bending stresses are introduced into the test gear tooth and the location of fatigue failure is predetermined with a high degree of confidence. The rotational orientation of the test gear is precisely established using setup tooling. The rod that loads the test tooth at the highest point of single tooth contact is representative of a rack gear (flat profile or infinite radius of curvature) contacting the test tooth. The various stages of fatigue crack growth can readily be observed through the viewing port provided. Figure 3 shows the test fixture ready for operation. During installation of the gear test assembly, extreme care was taken to ensure that the load rods were in exact alignment with the load line of the test system. Furthermore, the test fixture was designed such that the load line of the test system is tangent to the nominal involute base circle. Use was made of the clearances between the various bolts and bolt holes to make the necessary positional and angular adjustments. When proper alignment was achieved, both load rods moved freely in their respective bushings and exhibited minimum friction. A check of the performance of the fixture alignment was made using “machinists dye” (bluing) applied to the gear tooth profile prior to testing. The dye removal created by the load rod contact areas gave a clear indication that uniform load distributions on both gear

Figure 4: Test tooth contact pattern illus- trating evidence of uniform load distribution across the face width.

gearsolutionsonline.com • JANUARY 2008 • GEAR SOLUTIONS 21 For the testing conducted in this study crack initiation was assumed approximately 30 to 50 percent of the distance across the tooth thick- to occur when the loading rod stroke increased approximately 2 per- ness at the tooth base. To determine the extent of the crack face at cent (~0.0002 in. change) relative to the stroke for the gear tooth at the middle location across the tooth face width would require post-test test initiation. At this point a crack had initiated with a size on the removal of the tooth. An example of one of the test specimens is order of the case depth. The test was continued until the rod stroke shown in figure 6 at the test termination cycle limit. was 0.010 in. greater than that achieved on the new gear tooth. At this point the crack size was visible on the side of the tooth and was Number of teeth 28 Finite Element Gear Model Module, mm 3.175 In order to relate the normal load applied in the test to the fillet–root Diametral pitch (1/in.) 8 stresses that the loading would induce, a finite element model of two Circular pitch, mm (in.) 9.975 (0.3927) identical gears as shown in table 3 operating at a standard center dis- Whole depth, mm (in.) 7.62 (0.300) tance was analyzed via a specialty code developed for gears (ref. 11). Addendum, mm (in.) 3.18 (.125) The FEA modeling requires selection of the radius of the tip of the hob Chordal tooth thickness ref. mm (in.) 4.85 (0.191) that made the gear. In this work, a hob tip radius of 0.044 in. was used Pressure angle, deg. 20 to provide a gear root radius of nominal print dimensions. Assuming Pitch diameter, mm (in.) 88.90 (3.500) linear-elastic material response, the gear bending stress is propor- Outside diameter, mm (in.) 95.25 (3.750) tional to applied load. Therefore, the analysis was done for one load Root fillet, mm (in.) 1.02 to 1.52 case only and stresses for any load case found by linear scaling. For (0.04 to 0.06) the loads used in the experimental part of this study some plasticity Measurement over pins, mm (in.) 96.03 to 96.30 had to have occurred on a local level where the calculated linear-elastic (3.7807 to 3.7915) stresses (in the range of 290 to 650 ksi) exceeded the yield strength Pin diameter, mm (in.) 5.49 (0.216) of the material (290 ksi (ref. 4)). Therefore, the stresses reported Backlash reference, mm (in.) 0.254 (0.010) should be considered as stress-based indices of load severity, and the Tip relief, mm (in.) 0.010 to 0.015 (0.0004 to 0.0006) term “pseudo-stress” has been adopted to highlight the distinction. An Note: Gear tolerances are per AGMA class 11. example of the predicted distribution of maximum principal stress for TABLE 4.—BENDINGthe FATIGUE test specimen DATA is shown in figure 7. A 4000 lb normal force pro- Table 3: Test Gear Design Parameters duces a 379 ksi pseudo-stress maximum at the fillet-root region.

Specimen Specimen Minimum Tooth fillet Stroke Crack initiation Test number number load tensile psuedo- (in.) (cycles) termination (lbf) stress (cycles) (ksi) GT0014-1A –3500 –50 331 0.0141 4721 6413 GT0014-2A –3511 –115 332 0.0134 6679 7921 GT0014-4A –4105 –42 389 0.0159 855 1611 GT0014-3A –4081 –20 386 0.0159 1208 1999 GT0014-5A –3762 –25 356 0.0148 2181 3261 GT0050-C * –3494 –79 331 0.0134 2235 3675 GT0050-D * –3486 –77 330 0.0140 2108 3746 GT0021-1 –3687 –71 349 0.0143 4524 5820 GT0021-2 –3675 –61 348 0.0143 4170 5178 GT0021-3 –3680 –70 348 0.0142 3426 4578 GT0021-4A –3987 –62 377 0.0153 2151 3159 GT0021-5 –3984 –54 377 0.0154 1163 2315 GT0062-D * –3717 –37 352 0.0150 1095 2049 GT0062-C * –3715 –47 352 0.0145 2000 3024 GT0062-B * –3716 –39 352 0.0145 1638 3060 GT0062-NT ** –3750 –49 355 0.0144 1752 ---- GT0053-A –4194 –30 397 0.0165 1900 2599 GT0053-B –4199 –43 397 0.0169 1242 1667 GT0018-A –4242 –99 402 0.0165 462 1378 GT0018-B –4250 –100 402 0.0168 348 1034 GT0050-E –4714 –70 446 0.0190 190 668 GT0045-A –4750 –59 450 0.0189 638 858 GT0045-B –5015 –119 475 0.0200 460 755 GT0045-C –5002 –73 473 0.0201 498 725 GT0045-D –2994 –42 283 0.0123 14800 16167 GT0045-E –3004 –40 284 0.0122 16400 18315 *Test tooth had dithering-induced surface damage and had experienced low-load-level dynamic testing. **Test tooth was only tested to crack initiation. Table 4: Bending Fatigue Data

22 GEAR SOLUTIONS • JANUARY 2008 • gearsolutionsonline.com Figure 5: Applied loading and calculated tooth fillet (bending) stress as a function of time.

Figure 6: Single tooth bending failure at test termination.

Test Results A total of 29 fatigue and crack propagation tests were run. The data from these tests are shown in tables 4 and 5. In table 4, normal loads for the fatigue tests are listed. The fatigue test loads ranged from approximately 3000 to 5000 lbf compression (noted as nega- tive load in the tables). In table 5, a single load of increasing amount was applied using stroke control until the gear failed. The single 1/4 cycle load to failure ranged from approximately 5850 to 6900 lbf. Table 4 provides the initial stroke (total deflection of load rods, gear test and reaction teeth), the crack initiation cycles and the number of cycles to test termination. The specimen number is related to a particular gear and the tooth tested on that gear. The test fixture and gear design permitted up to five teeth to be tested on a single gear. The fillet pseudo-stress values shown from each test were based on proportional scaling of the maximum applied load to the load applied in the finite element model results mentioned earlier. Table 5 provides data for three tests conducted for single load to failure (1/4 cycle). These tests were conducted on previously untested gear teeth. The maximum bending stress is shown in the table (calculated as previously described) along with an equivalent load capacity of load per inch of face width. The tooth fillet region pseudo-stress ranged from 554 to 654 ksi and the load per inch of face width ranged from approximately 23000 to 27000 lbf per in. of face width. For the data of table 4, five of the tests were on gears that had been previously tested for another potential failure mode known as dithering. Dithering is small relative motion between meshing gears that can exhaust the contact of lubricant and cause fretting wear and fretting fatigue at the contact locations. Dynamic (rotating) testing was done on test specimens having dithering-induced damage for

gearsolutionsonline.com • JANUARY 2008 • GEAR SOLUTIONS 23 TABLE 5.—SINGLE LOAD TO FAILURE TEST DATA Specimen Fracture Load per in. Tooth fillet tensile number maximum of face width pseudo-stress (ksi) load (lb/in.) at fracture load (lbf) GT0053-C –6914 27656 654 GT0053-PF2 –6750 27000 639 GT0062-A –5848 23392 554

Table 5: Single Load to Failure Test Data millions of stress cycles (at a low level of fillet stress, in the range of 30 ksi). Five teeth with dithering-induced damage were tested during this research using the single-tooth bending method. These five tests showed that the bending fatigue strength was not compromised due to the fretting on the gear flank surface. The gear teeth failed at the usual site in the root and fillet region and not at the location of the dithering-induced damage on the active flank of the tooth. This indicated, based on the relatively low number of tests conducted, that a bending failure would not occur from a dither-damaged surface. One of the teeth tested had both fretting damage and contact-fatigue pitting damage present prior to single tooth bending testing. Testing of that gear resulted in fatigue cracks through the case in both the root-fillet region and on active flank where pitting was present. For that tooth, the cracks in the fillet region were larger than the crack in the pitting region. For purposes of the present research, it was assumed that the dynamic testing done at low levels of load on teeth with dither-induced damage did not represent any significant fatigue damage. That is, the low-load cycles were not included in the cycle- counting for purposes of reporting the data. All the data generated in this study for bending fatigue are shown in figure 8. Remember that the testing was unidirectional and that the fillet pseudo-stress values are stress-based indices of load intensity based on linear-elastic material response. Test termination data are plotted in figure 9. For the range of 200 to 20,000 cycles, the relationships of stress to cycles for crack initiation and to cycles for test termination were found to be semi-logarithmic. The relationship of load intensity to crack propagation cycles (defined as the differ- ence of crack initiation cycles and test termination cycles) is shown in figure 10. There is a linear relationship between level of stress and the cycles for crack propagation. In other words, lower load level

Figure 7: Finite element analysis result showing distribution of maximum principal tensile stresses for a unit load at the highest point of single tooth contact. The color key has units of psi for a unit load (1 lbf).

24 GEAR SOLUTIONS • JANUARY 2008 • gearsolutionsonline.com resulted in a lower percentage of total test cycles for crack References: propagation. 1) Fundamental Rating Factors and Calculation Methods for Involute Spur Summary and Helical Gear Teeth, ANSI/AGMA A series of single tooth bend- 2001-C95, October 1994. ing tests have been conducted 2) McIntire, W., Malott, R.; “Advancement on AISI 9310 spur gears. Tests of Spur Gear Design Technology”, were conducted from 1/4 cycle USAAVLABS Technical Report to thousands of cycles. The 66–85, U.S. Army Aviation Materiel tooth fillet region stresses Laboratories, Ft. Eustis, Virginia, reported were calculated using 1966. a linear-elastic finite element 3) Heath, G., Bossler, R.; “Advanced Figure 8: Single tooth bending data, crack initiation times. model. The reported values Rotorcraft Transmission (ART) for tensile stress exceeded Program—Final Report”, NASA the known yield properties of CR-191057, ARL–CR–14, 1993. the material for a small volume of material in the root- 4) Krantz, T.; “The Influence of Roughness fillet region, and therefore the on Gear Surface Fatigue”, Ph.D. Thesis, reported stress values should Case Western Reserve University, be considered as a stress- Cleveland, Ohio, USA, 2002; also based index of load intensity. NASA/TM—2005-214958, ARL– Testing produced cycle versus TR–3134, 2005. load relationships for crack 5) Townsend, D.; “Surface Fatigue Life initiation and crack propaga- and Failure Characteristics of EX53, tion. When tests were ter- CBS 1000M, and AISI 9310 Gear minated, the crack size as Materials,” NASA TP 2513, 1985. visible on the tooth side face 6) Townsend, D.; Chevalier, J.; Zaretsky, was approximately 30 to 50 E.: “Pitting Fatigue Characteristics of percent of the distance across Figure 9: Single tooth bending data, test termination the tooth thickness at the cycles. AISI M 50 and Super Nitralloy Spur tooth base. For the range of Gears,” NASA TN D–7261, 1973. 200 to 20,000 cycles, the 7) Krantz, T., Kahraman, A.; “An relationship of stress to crack Experimental Investigation of the initiation cycles and to test Influence of the Lubricant Viscosity termination cycles was found and Additives on Gear Wear,” NASA/ to be semi-logarithmic (linear TM—2005-213956, ARL–TR–3126, trend of stress versus log 2005. (cycles)). The relationship of 8) Handschuh, R., Morales, W.; stress to crack propagation “Lubrication System Failure Baseline cycles was found to be linear. For the range of loads investi- Testing on an Aerospace Quality Gear gated, the crack propagation Mesh,” NASA/TM—2000-209954, phase is dependent on the ARL–TR–2214, 2000. level of load applied, and can 9) Lewicki, D.; “Crack Propagation Studies be a relatively small part of To Determine Benign or Catastrophic the total test time (order of Failure Modes For Aerospace Thin-Rim 10~20 percent) for the lower Gears,” Ph.D. Thesis, Case Western load level used in this study. Reserve University, Cleveland, Ohio, The crack initiation data could USA, 1995, also NASA TM-107170, be used to validate methodol- ARL–TR–971, 1996. ogy for fatigue life evaluations. The crack propagation data could be used to validate method- 10) Dempsey, P.; “Integrating Oil Debris ology for damage-tolerance evaluations. Five fatigue tests were done using gear teeth having dithering-induced surface damage on the active tooth profile. The fatigue crack location was and Vibration Measurements for at the usual position in the root and fillet, not at the dithering-induced damage location. For Intelligent Machine Health Monitoring,” these five tests, the dithering-induced damage did not reduce the bending fatigue capability Ph.D. Thesis, University of Toledo, of the gear tooth. Toledo, Ohio, 2002, also NASA/ TM—2003-211307, 2003. 11) Vijayakar, S.; “Multi-body Dynamic About the authoRs: Contact Analysis Tool for Transmission Robert F. Handschuh and Timothy L. Krantz are with the U.S. Army Research Laboratory, Design – SBIR Phase II Final Report,” Bradley A. Lerch is with the National Aeronautics and Space Administration, Glenn ARL–CR–487, 2003. Research Center, and Christopher S. Burke is with the QSS Group, Inc.

gearsolutionsonline.com • JANUARY 2008 • GEAR SOLUTIONS 25 Natural Frequencies and Modal Properties of Compound Planetary Gears

All vibration modes can be classified into one of three types—rotational, translational, and planet modes. In this article the author provides a detailed description. By Robert G. Parker, Ph.D.

26 GEAR SOLUTIONS • JANUARY 2008 • gearsolutionsonline.com This paper presents the structured vibration mode and natural fre- cal examination of the structured modal properties of planetary gears quency properties of compound planetary gears of general descrip- of very general description. Kahraman [3] considered a more limited tion, including those with equally-spaced planets and diametrically study of the vibration of compound planetary gears. In that work, opposed planet pairs. The vibration modes are classified into rota- a purely rotational model that does not include gear translation is Ttional, translational, and planet modes and the unique properties of applied to a restricted class of compound planetary gears, and modal each type are examined and proved for general compound planetary properties are given based on simulation rather than derivation. gears. All vibration modes fall into one of these three categories. For simple, single-stage planetaries, Lin and Parker [4] analyzed the free vibration and proved that there are exactly three types of modes: rotational, translational, and planet. They showed certain Introduction unique properties for these modes. These findings are consistent Planetary gears are widely used in many applications due to advan- with finite element results [8]. Recent industry-motivated analyses tages over parallel shaft arrangements such as high power density by the authors investigated a variety of compound and multi-stage and large reduction in a small volume [1]. In fixed-ratio applications planetary gearsets and found that they all exhibited modal character- requiring a reduction of approximately 10:1 or less, a simple (i.e., istics similar to a simple, single-stage planetary gear. The intent of single planet for each load path), single-stage planetary gear is this work is to generalize prior results and mathematically prove that often sufficient. For fixed-ratio applications requiring greater reduc- compound, multi-stage planetary gear systems of general description tions, however, compound planetary gears are common. Automatic possess highly structured modal properties analogous to simple, transmissions require more kinematic combinations than a single single-stage planetary gears. planetary can provide, so they also utilize compound planetary gears. Despite their benefits, compound planetary gears often have more noise and vibration problems than simple planetary gears. Modeling and Equations of Motion Although the vibration of simple, single-stage planetary gears There are many different kinds of gearsets that are referred to as has been studied by many researchers (e.g., [4]- [16]), the vibration compound planetary gears. The present work attempts to be as gen- of compound or multi-stage planetary gearsets has received little eral as possible in its definition. Three different types of compound research attention. Kiracofe and Parker [2] conducted a mathemati- planetary gears are described. The first two are the stepped planet

gearsolutionsonline.com • JANUARY 2008 • GEAR SOLUTIONS 27 A One Planet Train Ring Carrier Planet 2 Planet 1 Figure 1: Example of a stepped planet Sun compound planetary Sun gear.

Ring Planet 1 Planet 2 One Planet Carrier Train

A Figure 2: Example of a meshed planet SECTION A-A compound planetary gear. planetary (Figure 1), and the meshed planet is convenient to divide them into groups. where designates the number of planet planetary (Figure 2) [17]. The third type, the First, each planet is always associated with trains in planet set i. Let the planets in a multi-stage planetary, (Figure 3) is created one and only one carrier. Thus, it is natural train be numbered 1,2,..., , where desig- by joining multiple planetary stages together, to define a planet set to be all of the planets nates the number of planets per planet train where each stage can be a simple, meshed, associated with a particular carrier. Within in planet set i. The model requires all planet or stepped planetary. No limitations are each planet set, the planets are partitioned trains in a planet set to have the same num- imposed on which elements are the input or into isolated planet trains. Two planets are ber of planets, which is generally the case in output members. considered to be in the same planet train practical systems. In deriving the equations of motion, it is if they: a) mesh with each other, or b) are A planar problem is considered where necessary to systematically enumerate the connected to each other by a shaft (as in each carrier, planet, and central gear has three types of elements in a planetary gear: stepped planets). The planet train concept is three degrees of freedom: two translational and one rotational. The model has carriers, central gears (suns and rings), illustrated in Figures 1 and 2. and planets. Let the carriers be numbered Let the planet sets be numbered 1,2,...,a, degrees of freedom. 1,2,...,a and the central gears be numbered where planet set i is associated with carrier i. 1,2,...,b. In order to describe the planets, it Let the planet trains be numbered 1,2,..., ,

28 GEAR SOLUTIONS • JANUARY 2008 • gearsolutionsonline.com Planet Train 1 First Second stage stage Gear 2

Planet Set 1 Planet Set 1 Input (first Output (second Planet 2 Planet 3 stage carrier) Carrier 2 stage sun) Planet Set 2 Connecting Planet 1 Planet Set 1 shaft Planet 1

Carrier 1 Gear 1 Gear 3

Figure 3: Example of a multi-stage compound planetary gear. Figure 4: Example system.

Translational coordinates are assigned to the carriers and translational coordinates are assigned to the central gears (suns and rings). The and coordinates are positive towards the equilibrium position of the arbitrarily chosen first planet of the first planet train of the first planet set at time t=0. Translational coordinates are assigned to planet m in planet train l in planet set i. These are radial and tangential coordinates. The equations of motion of a central gear are discussed as an example. The forces/ moments on a central gear fall into five categories: gear-gear forces/moments, gear-carrier forces/moments, gear-ground bearing forces/ moments, gear-planet mesh forces, and externally applied forces/moments. The first three are easily described. Modeling the interaction as a linear spring, such as from a connecting shaft, the gear-gear force between gears j and n in the x direction is described by . Similar terms occur for the y and coordinates as well as the gear-carrier and gear-ground forces/moments. Note that central gears never mesh with other central gears. Gear-planet mesh forces are more described in [2]. The equations of motion for the planets, central gears, and carriers are given in [2]. The equations of motion for the full system are written in matrix form as

(1)

Natural Frequencies and Vibration Modes To determine the natural frequencies and vibration modes the time-invariant system is considered. All mesh stiffnesses are considered to be constant and equal to their average stiffness over one mesh cycle. All externally applied forces/moments are assumed to be zero. The associated eigenvalue problem derived Table 1: Parameters of example system in Figure 4. from is

gearsolutionsonline.com • JANUARY 2008 • GEAR SOLUTIONS 29 Stage 1 (2)

(3)

The individual vectors for the carriers and gears are

(4)

The planet set, planet train, and planet vectors are

(5)

Stage 2 Expanding (2) into three groups of equations for the individual components according to the matrix definitions yields

(6)

(7)

(8)

Figure 5: Typical rotational mode for example system of The following additional assumptions are imposed: Figure 4 and Table 1, w=932.0 Hz. 1. All planet trains within a planet set are identical in all ways (mass, tooth parameters, bearing properties, etc.). 2. All planet trains are equally spaced around their associated carrier. The case with diametrically opposed pairs of planet trains is discussed later.

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30 GEAR SOLUTIONS • JANUARY 2008 • gearsolutionsonline.com Stage 1 Stage 1

Figure 7: Two typical planet modes for the example system of Figure 4 and Table 1. (left) A mode in which stage 1 planets have motion and stage 2 has no motion, w=2382.2 Hz. (right) A mode in which stage 1 has no motion and stage 2 planets have motion, w=3890.2 Hz. Stage 2 Stage 2 sidered later as a case of diametrically opposed planet trains. 4. All bearing and shaft stiffnesses are isotropic.

The distinctive vibration properties are first illustrated by an example using the parameters in Table 1. This system is shown schemati- cally in Figure 4. It is a two stage system where the first stage has both meshed and stepped planets and the second stage has only simple planets. The ring gear is common to both stages. The system has 66 degrees of freedom. The natural frequencies and their multiplicities are shown in Table 2. Figure 6: A pair of typical translational modes for example sys- All vibration modes for this system can be classified into one of three tem of Figure 4 and Table 1, =9499.2 Hz. w types. Typical vibration modes of each type are shown in Figure 5-Figure 3. For each planet set i, . In practice, almost all planetary 7. The equilibrium positions of the gears and carriers are shown as gears have three or more planets to take advantage of load dashed lines. The equilibrium positions of the planets with respect to the sharing. The case with two equally spaced planet trains is con- displaced carriers are shown as light lines. The displaced positions of

gearsolutionsonline.com • JANUARY 2008 • GEAR SOLUTIONS 31 the suns and planets are shown as heavy lines. Dots represent the component centers. Motion of the ring is omitted for clarity. Figure 5 illustrates a type of mode where all central gears and carriers have pure rotation and no translation. These are named rotational modes. In a rota- Natural Frequency (Hz) tional mode, all planet trains within a given planet set have identical motion. There are exactly rotational modes, each with an associated

m=1 m=2 natural frequency of multiplicity one (distinct). Figure 6 shows a pair of degenerate modes that have the same natural fre- 0.0 R 442.2 T quency. All central gears and carriers have pure translational motion with no 660.9 P 771.3 T rotation. These are called translational modes. There are exactly degenerate pairs of translational modes, where each pair has an associated 932.0 R 1029.5 P natural frequency of multiplicity two. Well-defined relations between the planet 1011.2 R 1436.5 T motions will be shown. Figure 7 illustrates two modes where the carriers and central gears have no 1261.4 R 1856.2 T motion; the planets are the only components that deflect. These are called planet modes. A given mode is associated with motion of the planets of exactly 1557.1 R 2250.2 T one planet set and planets in all other planet sets have no motion. In general, each natural frequency associated with planet set i has multiplicity – 3. Thus, 2382.2 P 3499.2 T planet modes exist only for planet sets containing four or more planet trains. If planet modes exist for planet set i, then there are different natural fre- 3379.0 R 3890.2 P quencies for that set’s planet modes (each with multiplicity -3). So, there are exactly planet modes. 3796.3 R 4491.2 T The number of different natural frequencies for a planet set’s planet modes is 4849.2 R 4802.9 P dictated by the number of degrees of freedom in one planet train; their multiplicity is dictated by the number of trains in the set. Finally, each planet train’s 5811.5 P 5503.2 T motions are a scalar multiple of the first (or any arbitrarily chosen) planet train’s motions. Equations governing these scalars will be derived. 5860.6 R 5553.4 T The above properties of the modes, which have been drawn from numerical results, can be proven analytically [2]. The proof proceeds by proposing 5991.1 P 5936.4 T candidate modes based on the numerical results and substituting them into the equations of motion. For each type of mode, a reduced degree of freedom 6019.5 R 6141.3 T eigenvalue problem is found. The total number of eigenvalues is shown to equal 6247.8 P 7796.3 T the total number of degrees of freedom in the system, so the three mode types are an exhaustive list of the possible mode types. 6597.2 R 8360.2 T 6981.1 R 8812.4 T Rotational Modes A rotational mode has the form (3) - (5) simplified as 7180.6 P 9117.1 T (9) 7767.1 R 10083.9 T Algebraic reductions of (6) - (8) yield an order 8339.6 P 11071.6 T reduced eigenvalue problem involving the non-zero degrees of freedom in (9). 8564.8 R Its solution gives natural frequencies and rotational modes.

10082 .7 P From the solutions of the reduced eigenvalue problem, rotational vibration modes of the full system are constructed according to (9). These eigenvalues 10085 .6 R are distinct, in general.

10982 .1 R 11054 .3 P Translational Modes A pair of translational modes of the form (3) - (5) with degenerate natural fre- 11092 .6 R quency is given by

Table 2: Natural frequencies and their multiplicities m for the example system. Rotational, translational, (10) and planet modes are distinguished by R, T, and P, respectively. (11)

1 Note the sign differences between (13) and the corresponding equation in Lin and Parker’s derivation [4]. This is a typographi- cal error in [4] that is corrected in this paper.

32 GEAR SOLUTIONS • JANUARY 2008 • gearsolutionsonline.com These are orthogonal with respect to the mass matrix such (15) that . The carrier, gear, and planet translations are related by1 (16) (12) with defined in (5) and denoting a particular planet set. Insertion of (15) - (16) into (6) - (8), expansion using matrix definitions, and use of algebraic reductions similar to

those for rotational and translational modes yields the reduced order eigenvalue problem for the motion of a single planet train (13) (17)

There are eigensolutions of the reduced problem (17). The (14) eigenvalues are distinct, in general. It remains to determine the in (16). Examination of the forces acting on the system for deflection in a planet mode yield three constraints on the [2] where , and I is the 3x3 iden- tity matrix. It remains to show that this candidate mode pair satis- (18) fies (6) - (8), and this is presented in detail in [2]. Thus, if all planet sets have three or more planet trains, then there are i Ambarisha and Parker [9] proved that for a simple planetary

gear the number of independent solutions of (18) is exactly numerically different translational natural frequencies, each with . Thus, planet modes exist only for planet sets with four or multiplicity two. more planet trains. Wu and Parker [7] give the following closed-form, independent solutions based on their consideration Planet Modes of simple planetary gears A planet mode associated with planet set i is written in the form (19)

gearsolutionsonline.com • JANUARY 2008 • GEAR SOLUTIONS 33 The rotational and planet modes retain their properties in the diametrically opposed case. The translational modes, however, (20) are modified for the diametrically opposed case. Specifically, translational modes have distinct eigenvalues instead of multiplicity two, but they retain their modal character of the suns, where the brackets in (19) and (20) denote the ceiling and floor rings, and carriers having only translation and no rotation. functions, respectively. For each eigensolution of the reduced problem (17), independent vibration modes of the full problem (1), each having Discussion the same natural frequency, are constructed from (15), (16), and While the mathematical proof is of interest mainly to the academ- the independent solutions of (18). Thus, for each planet set ic researcher, the results are useful for both the practical gearbox there are vibration modes of the form (15)-(16); designer and the academic researcher. To a gearbox designer, these are grouped into sets of degenerate modes, where each set the prediction of natural frequencies allows resonance condi- has an associated natural frequency of multiplicity . tions to be avoided when designing a planetary gear system. The classification of modes into various types and knowledge of the number of numerically different natural frequencies is also Diametrically Opposed Planet Positions important for avoiding resonant response, reducing excitation of In certain situations, assembly constraints cause the planet trains particular mode types, and understanding whether response in to be unequally spaced around the carrier. In the general case, a particular mode will generate torque (rotational modes), force this causes the rotational and translational modes to couple and (translational modes) or neither (planet modes) to the structures lose their distinctive properties. One special case of interest is supporting the central gears (sun and ring). In cases where the diametrically opposed case in which pairs of planets trains design constraints require operating tooth mesh frequencies to are 180 deg apart. In other words, for some is even, be near natural frequencies, the use of planet mesh phasing can and . This is common in practice. Each pair suppress resonant response [9], [14], [18], [19]. Understanding may be arbitrarily spaced. is allowed, which is an excep- and application of planet mesh phasing depends on the unique tion to assumption 3. For , the terms “equally spaced” and properties of planetary gear free vibration as shown here. Future “diametrically opposed” are equivalent. The properties of such a work on understanding the various mode types may identify cer- planet set follow the results for the diametrically opposed case. tain types of modes as having more significant impact on noise, Lin and Parker considered diametrically opposed planets for a fatigue life, and other factors of interest. simple, single stage planetary gears in [12]. For research purposes, extension of the dynamic model of sim-

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34 GEAR SOLUTIONS • JANUARY 2008 • gearsolutionsonline.com ple planetary gears to the general compound case allows other Journal of Applied Mechanics. In press. investigations of simple planetary gear vibration to be extended 8. Parker, R. G., Agashe, V. and Vijayakar, S. M., 2000, “Dynamic to the compound case. Research on nonlinear response, para- Response of a Planetary Gear System Using a Finite metric excitation from fluctuating mesh stiffness, elastic ring Element/Contact Mechanics Model”, Journal of Mechanical deformation, etc. (e.g.,[7], [8], [10], [20], [21], [22]) can be Design, 122, pp. 305-311. carried out for general compound planetary gears. These analy- 9. Ambarisha, V. K. and Parker, R.G., 2006, “Suppression of ses benefit from understanding the properties of the different Planet Mode Response in Planetary Gear Dynamics through mode types, particularly because such analyses frequently adopt the assumption that only one or two modes are present in the Mesh Phasing”, Journal of Vibration and Acoustics. 128, pp. response (modal truncation). In that case, one can examine the 133-142 interactions between two modes of the same or different types. 10. Ambarisha, V. K. and Parker, R. G., 2006, “Nonlinear For example, is a combination parametric instability possible Dynamics of Planetary Gears using Analytical and Finite between a rotational and translational mode? Element Models”, Journal of Sound and Vibration. 302, pp. 577-595. 11. Kahraman, A., 1994, “Natural Modes of Planetary Gear Summary and Conclusions Trains”, Journal of Sound and Vibration. 173 (1) pp. For identical, equally spaced planet trains, the natural frequen- 125-130. cies and vibration modes of compound planetary gears have 12. Lin, J. and Parker, R. G., 2000, “Structured Vibration highly structured properties due to the system’s cyclic sym- Characteristics of Planetary Gears with Unequally Spaced metry. Specifically, all vibration modes can be classified into Planets”, Journal of Sound and Vibration. 233 (5) pp. one of three types: rotational, translational, and planet modes. 921-928. Rotational modes with distinct natural frequencies have pure 13. Lin, J. and Parker, R. G., 2001, “Natural Frequency Veering rotation of the central gears and all planet trains in a given planet set move identically. Pairs of translational modes with in Planetary Gears”, Mechanics of Structures and Machines. degenerate natural frequencies have pure translation of the car- 29 (4), pp. 411- 429. riers and central gears, and motions of the planet trains in a 14. Parker, R. G., 2000, “A Physical Explanation for the pair of orthonormal vibration modes can be found by a simple Effectiveness of Planet Phasing to Suppress Planetary Gear transformation of the first planet train’s motion. Planet modes Vibration”, Journal of Sound and Vibration. 236 (4) pp. have motion of the planets in one planet set only and no motion 561-573. of any carriers or central gears; the multiplicity of their natural 15. Lin, J. and Parker, R. G., 1999, “Sensitivity of Planetary frequencies is dictated by the number of planet trains in a planet Gear Natural Frequencies and Vibration Modes to Model set. Reduced order eigenvalue problems for each mode type are Parameters”, Journal of Sound and Vibration, 228 (1), pp. given explicitly. 109-128. 16. Cunliffe, F., Smith, J. D. and Welbourn, D. B., 1974, “Dynamic Tooth Loads in Epicyclic Gears”, Journal of Engineering for References Industry, 96 (2), pp. 578-584. 1. Smith, J. D., 1983, Gears and Their Vibration: A Basic 17. Müller, H. W., 1982, Epicyclic Drive Trains: Analysis, Synthesis, Approach to Understanding Gear Noise. and Applications. Translated from German by Manhardt, W. G. 2. Kiracofe, D. R. and Parker, R. G.., 2007, “Structured Vibration 18. Seager, D. L., 1975, “Conditions for the Neutralization of Modes of General Compound Planetary Gear Systems”, Excitation by the Teeth in Epicyclic Gearing”, Journal of ASME Journal of Vibration and Acoustics. 129, pp. 1-16. Mechanical Engineering Science. 17 (5), pp. 293-298. 3. Kahraman, A., 2001, “Free Torsional Vibration Characteristics 19. Kahraman, A. and Blankenship, G. W., 1994, “Planet Mesh of Compound Planetary Gear Sets”, Mechanism and Machine Phasing in Epicyclic Gear Sets” Proceedings of International Theory. 36, pp. 953-971. Gearing Conference, Newcastle, UK, pp. 99-104. 4. Lin, J. and Parker, R. G., 1999, “Analytical Characterization 20. Kahraman, A., Kharazi, A. A., and Umrani, M., 2003, “A of the Unique Properties of Planetary Gear Free Vibration”, Deformable Body Dynamic Analysis of Planetary Gears with Thin Journal of Vibration and Acoustics. 121, pp. 316 – 321. Rims”, Journal of Sound and Vibration. 262, pp. 752-768. 5. Sun, T. and Hu, H. Y., 2003, “Nonlinear Dynamics of a 21. Lin, J. and Parker, R. G., 2002, “Planetary Gear Parametric Planetary Gear System with Multiple Clearances”, Mechanism Instability Caused by Mesh Stiffness Variation”, Journal of and Machine Theory. 38, pp. 1371-1390. Sound and Vibration. 249 (1), pp. 129-145. 6. Saada, A. and Velex, P., 1995, “An Extended Model for the 22. Velex, P. and Flamand, P., 1996, “Dynamic Response of Analysis of the Dynamic Behavior of Planetary Trains”, ASME Planetary Trains to Mesh Parametric Excitations”, Journal of Journal of Mechanical Design 117, pp. 241-247. Mechanical Design. 118, pp. 7-14. 7. Wu, X. and Parker, R. G., 2007, “Modal Properties of Planetary Gears with an Elastic Continuum Ring Gear”,.ASME

About the authoR:

Robert G. Parker, Ph.D., is a professor in the Department of Mechanical Engineering at The Ohio State University. He can be reached at (614)292-3922 or [email protected]. Go online to [www.mecheng.osu.edu].

gearsolutionsonline.com • JANUARY 2008 • GEAR SOLUTIONS 35 A Revelation in Advanced Software Technology By George Nelson Here are details on a new software package that increases productivity, decreases programming, setup, and cycle times, and leads to greater profitability.

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gearsolutionsonline.com • JANUARY 2008 • GEAR SOLUTIONS 37 Versatile Features

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REVELATIONS is intelligent, easy-to-use Currently running on a number of new V ersatile software that can be adapted for any and remanufactured grinding machines, machine tool that uses a PC-based con- REVELATIONS has proven itself as a tre- trol. With touch-screen controls and a mendous tool on the production floor. familiar, simple operator interface, it is With one customer’s part, cycle time was a powerful productivity tool for any pro- reduced from 157 to 29 seconds—a total duction floor. Faster operator training, savings of over two minutes per part. On thousand loss statements. The same code programming, setup, and cycle times, and that one machine alone the customer is in REVELATIONS would appear as: less scrap all contribute to lower overhead realizing a savings of more than $625,000 and increased profitability. per year. At that customer’s shop rate, G1G90X100 “We created REVELATIONS in response even a one-second cycle time reduction G1G90X101 to flaws we saw in our own and other can translate to an annual cost savings of G1G90X101.1 companies’ control software and estab- up to $36,000. G1G90X101.2 lished the benchmark for CNC software in the machine tool industry,” says Craig As experienced using a GE Fanuc 30i B. Barrett, president and CEO of Bryant Faster Cycles, Increased ROI control, and using the same formula, Grinder, a division of Vermont Machine Cycle time reductions come both from the REVELATIONS software eliminates the Tool. “In an era of increasing global streamlined G-code and the flexibility of 10ms delay for each of the three “if” competition, for large manufacturers and REVELATIONS. Canned G-code might look statements, reducing cycle time on those small job shops alike, it’s no longer busi- like the following example: three statements alone by 30ms. For ness as usual. Any shop or manufacturer every 100 loss statements eliminated, using CNC machine tools can benefit from G1G90X100 cycle time is reduced by one second and, installing REVELATIONS software, maximiz- If [#500EQ1]GOTO10 for example, at a customer’s shop rate of ing their production and increasing profit- G1G90X101 $150, profitability is increased by as much ability.” If [#501EQ1]GOTO10 as $36,000. G1G90X101.1 Three-Button Operations If [#502EQ1]GOTO10 Based on Microsoft’s Windows, G1G90X101.2 Logical, Visual, and No Limits REVELATIONS has just one programming REVELATIONS was developed by Bryant screen with logical, visual flow charts to machine operators, manufacturing engi- Depending on the machine’s control, speed machine programming. With its neers, and control software engineers. each “if” statement, each math state- unlimited sequence capability and self- Their goals were to create control software ment, or each “think” statement can result configurable software, it lets users create that minimized screen navigation and was in up to 10ms delay in cycle time due to a process with no limitations, making the easy for both programmers and operators line-by-line block processing time. In this machine faster, more flexible, and easier to use. REVELATIONS’ design allows users example there are three delay statements to operate. to call up any function or operation with for a loss of 30ms. Every hundred loss Programmers design custom machine three button pushes or less, increasing statements results in an additional one cycles in any sequential order. Then the machine flexibility and reducing both setup second of cycle time on every part. A software automatically generates the and part-cycle time. typical canned cycle may contain several

38 GEAR SOLUTIONS • JANUARY 2008 • gearsolutionsonline.com • Single screen flowchart programming, and single screen for set-up and run. • Supports any number of axes in any combination; any number of wheel, work and dresser spindles; all standard types of Versatilegrinds and dresses including contour and profile;Features multi-path operations, including simultaneous operations in multiple paths; any number of programmable devices including loaders, gauges, wheel balancing; and any number of programmable trigger inputs from the machine: switches, positions, registers. • Any combination or sequence of grinds, dresses, devices or other operations in any cycle. • Grinds and dresses can contain any combination of nested operations: feeds, reverse feeds, dwells, and others. • Skip dressing and any other desired program branching. • Wheel, work, and dresser RPM adjustable at any point in a programmed cycle, as are oscillation parameters. • Recognizes and translates G-code programs, and programmer can view and edit ladder from the PC. • Servo parameters viewed and programmed from the PC. • Ethernet connection to customer LAN for remote programming, and telemaintenance via Ethernet for real-time trouble- shooting and software updates. • Alarm, user log, and cycle operation history. • Multiple password levels, and run-time strip chart of wheeldrive horsepower, servo load, and multiple configurable events. • Simulation mode for proving part programs, and context-sensitive help and complete user’s manual.

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gearsolutionsonline.com • JANUARY 2008 • GEAR SOLUTIONS 39 actions that range from gauge stages and stock sensors to push-buttons, softkeys, and position triggers, among others. In addition, the software recognizes any number of programmable devices, including gauges, loaders, fluid control, counters, and others. REVELATIONS incorporates adaptive features including horsepower grinding, CBN adaptive dress, adaptive skip dressing, acoustic dressing, and out-of-round grinding, with built-in learn- ing capabilities. It can even add multiple axes on the fly. Setup features are simplified by a graphi- cal operation sequence display. Operators can position the machine by touch or data entry and can direct operations to be skipped. There is a size correction grid, a tool offset grid, and path enable/disable, allowing the operator to customize the operations needed to complete a particular part. Logical sequencing, pop-up windows, online manuals and schematics, and context sensitive help screens guide the operator through each step in the process, minimizing operator errors during machine start-up or part changeover. Machine monitoring screen showing wheel power graph. G-code and downloads it into the control. grind surfaces, individual grind states, dresses, Unlike software using canned or macro-grind and operations. Automatic Configuration cycles that can drastically limit production times, The programmer enters the operation REVELATIONS was designed for maximum flex- REVELATIONS allows the programmer and oper- sequences such as route moves, dwells, device ibility. It automatically reconfigures itself to run ator to customize the cycle to best fit part and toggles, decision branching, and custom G-code. virtually any grinder, lathe, machining center, hob- production requirements, with any number of There are user-selectable trigger and event inter- ber, gear shaper, or special machine that uses a PC-based controller. It recognizes the number of axes, spindles, peripheral devices, and other features on the machine. Just by reading a list- ing of those items, it automatically reconfigures itself for that machine. REVELATIONS must be purchased for and installed on each machine it controls. With only one screen to run the entire machine, it reduces operator training time from days to a few hours. Operators quickly become familiar with the common interface and can be easily cross-trained to run multiple machines. Cross-training and faster training times contribute to a company’s lean initiatives, allowing for greater employee mobility and flexibility. REVELATIONS graphically displays dressing forms and grinding profiles, and its built-in intelligence helps prevent the machine from crashing and creating bad parts. Monitoring machine operation becomes much simpler with REVELATIONS’ graphing features, cycle time breakdowns, and log files that include cycle, operator, and machine logs.

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40 GEAR SOLUTIONS • JANUARY 2008 • gearsolutionsonline.com reaches the production floor. This type of simulation reduces setup time the operator’s manual and schematics not only lessened downtime, it and lets the engineer manipulate cycles to fit production requirements. eliminated the burden of cataloging the machine documentation.” With its optional Ethernet capability, REVELATIONS lets Bryant engineers troubleshoot and often resolve software, hydraulic, pneumatic, or electri- The Traditions of the Precision Valley cal issues for machines anywhere in the world, minimizing downtime and Since 1909 Bryant Grinder has been manufacturing innovative, state-of- reducing the need for service trips. the-art grinding machines and spindles designed for high-productivity and high-precision applications. As a recognized leader in the field of precision grinding, Bryant offers a complete line of CNC controlled grinding equip- Online Documentation ment, new parts, new spindles and spindle remanufacturing services of all For both machine operators and maintenance personnel, a “help” menu types and different manufacturers. Vermont Machine Tool was founded in accesses all documentation, with hyperlinks for each and every stage of 1983, specializing in remanufacturing, retrofitting, retooling, and moderniz- the process. All hydraulic, electrical, and pneumatic diagrams are also ing high quality machine tools to today’s exacting standards. Bryant Grinder available on the machine. merged with Vermont Machine Tool in 2002, maintaining the long-standing According to Robby Little, a Bryant software engineer instrumental in machine tool manufacturing tradition of Vermont’s Precision Valley. developing REVELATIONS, “When I was a service technician, when I arrived “Over the course of time, so many machine tool innovations have come on site to make repairs, more often than not the customers didn’t have out of this region,” Barrett says, “and we’re proud of our heritage and con- the necessary documentation for me to do my work,” he says. “Digitizing tinue to combine ‘Yankee ingenuity’ with advanced technology.”

NOTES: REVELATIONS™ is a trademark of Vermont Machine Tool Corporation. Bryant® and Bryant Grinder® are registered trademarks of Vermont Machine Tool Corporation. Bryant Grinder is a division of Vermont Machine Tool Corporation. Vermont Machine Tool® is a registered trademark of Vermont Machine Tool Corporation.

About the authoR:

George Nelson is sales manager for Bryant Grinder. To learn more call (802) 885-5161 or go online to [www.bryantgrinder.com]. To contact Vermont Machine Tool call (802) 885-4521 or go to [www.vermontmachinetool.com].

STOR-LOC MODULAR DRAWER SYSTEM 880 N. Washington Ave. Kankakee, IL 60901 Toll Free: 1.800.786.7562 • Fax: 1.800.315.8769 email: [email protected] www.storloc.com

gearsolutionsonline.com • JANUARY 2008 • GEAR SOLUTIONS 41 < Continued From Pg 13 Sunnen to Demonstrate New Machine at forward to developing stronger relationships with those custom- WESTEC ers in the Southeast, as well.” In addition to the new facility, Advanced Heat Treat has recently completed expansions within its facilities in Waterloo, Iowa, and Monroe, Michigan. The company offers comprehen- sive heat treating processes, over 40 vessels and furnaces, 60-plus expert technicians, a fully staffed metallurgical department, and uncompromising customer service. To learn more call (319) 232-5221 or go to [www.ahtweb.com]. New Dimensional Metrology Catalog From Mahr Federal Mahr Federal has issued a new catalog covering the full range of the company’s dimensional metrology instruments. At over 530 pages, and printed in full color, the catalog provides complete specification and ordering information on the company’s precision gages; metrology systems; and repair, training, and calibration services. In addition, the catalog incorporates a wealth of information on surface and contour, form, precision length, and shaft measurement, as well as on multisensor CMMs. New products described in the catalog include:

• Digital Calipers and Depth Gages • MarCator 1081 and 1088 Digital Indicators • Digimar® 817 CLM Height Gage • MarWin Software Platform

• Form Measurement Systems Sunnen’s new SV-1015 series vertical CNC honing system • Surface and Contour Measurement Systems with integrated air gaging system will be demonstrated at • Precision Length Systems WESTEC booth No. 2916. The event will be held at the Los Angeles Convention Center March 31-April 3, 2008. Matched • Shaft Measurement Systems with Sunnen’s diamond-plated CGT Krossgrinding® tools or MMT TurboHone® multi-stone mandrel, the air-gage-equipped Mahr Federal Inc.—a member of the Mahr Group—is machine can automatically control hole size to accuracies of known worldwide for 0.25µm (0.00001") without operator intervention, working in its expertise in provid- a size range of 3-65 mm (0.120-2.56") diameter. The new ing dimensional mea- machine provides closed-loop control of tool size, along with surement solutions. downloadable SPC data, making it ideal for automated, high- The ISO 9001:2000 Cpk production of small engines, hydraulic valves/bodies, fuel certified company injectors, gears, compressor parts, turbocharger housings, and manufactures and gun barrels, in medium and high volumes. markets a wide vari- According to Tom Dustman, sales manager for Sunnen ety of dimensional Products Company, by combining the new air gaging system metrology products, with the machine's patent-pending tool-feed control, the and is headquar- SV-1005 eliminates the need for an experienced honing opera- tered in Providence, tor to tweak the process. The new Etamic air gaging system Rhode Island. For a controls bore diameter and geometry by taking post-process free copy of the measurements of the parts while they are still fixtured on the new Mahr Federal machine’s rotary table. Feedback from air gage provides the catalog call (800) highest possible accuracy for tool-feed control. 333-4243 or (401) The SV-1005 matches an ultra-precise tool feed system with 784-3100. Send CNC control to allow any CNC-experienced machinist to master e-mail to informa- honing quickly. Setup is simple with a 3-axis hand wheel for [email protected], or fine tuning the tool feed and the servo-controlled stroke system visit [www.mahr.com]. and rotary-table. The control includes several features that put honing expertise at the fingertips of novices, such as a switch- able autocorrect feature for bore shape. Using measurements

42 GEAR SOLUTIONS • JANUARY 2008 • gearsolutionsonline.com Learn about Makino's new solutions for machining shaped from the air-gage system, it allows the operator to select from fine holes and how this process can benefit your manufactur- a library of “problem” bore images (taper, barrel, etc.) to match ing operations. to the part on the machine. The servo-controlled stroke system ensures a consistent crosshatch pattern and can dwell in any • Feb. 28—How to Get the Most Out of Your Work Zone. Hear part of the bore, end-to-end, selectively removing stock for how Makino achieves greater productivity and high quality ultra-precise straightness and roundness. production by maximizing utilization of the entire work zone The vertical design of the SV-1005 conserves shop floor of a horizontal machining center. There are multiple elements space, requiring just 2400 x 2300 x 2700 mm WxDxH (95 to consider, from machine design to processing techniques x 91 x 107 in.). A cast polymer base and cast-iron column and technologies that can be applied to improve your bottom provide enhance vibration damping for precision honing, while line. Learn how you can achieve accurate results, even while removable stainless steel side doors facilitate integration with automatic part loading systems. The high-torque, belt-driven cutting high in the Y-axis. spindle is rated at 7.5 kW (10 hp) to cover a wide range of sizing and finishing work using Sunnen’s MMT TurboHone multi- • March 13—Remote Machine Monitoring. Your shop is stone mandrels, TC precision mandrels, or CGT Krossgrinding closed, but the machines are still running. See how you can tools. monitor your shop's production from anywhere with an inter- For additional information call (800) 325-3670 or send e-mail net connection. to [email protected]. Go online to [www.sunnen.com]. • March 20—Hardmilling and Wire EDM, Complimentary Makino Announces Webinar Schedule Processes. Learn how to combine hardmilling and wire EDM Makino has released its 2008 first quarter webinar schedule, processes to reduce overall lead times. See examples of kicking off the new year with topics such as EDM for Aerospace actual parts processed using both operations and learn and Automated Five-Axis Machining. “Machinists today need about some of the practical limitations with combining these an arsenal of knowledge to tackle difficult and complex parts,” says Mark Rentschler, Makino’s marketing manager. “We’re cutting methods. always excited to share our innovative technologies and applications expertise to help shops in North America compete.” • March 27—New Five-axis Machining Solutions from Makino. Makino’s Online Seminar Series began in 2005 and is the Aside from the traditional advantages of five-axis machin- only expansive educational program offered by a machine tool ing, learn how new levels of sustained dynamic accuracy are builder free of charge. Thousands of shops have attended the being achieved through technologies which improve thermal over 60 webinars already broadcast. All webinars are broad- stabilization and maximize volumetric accuracy. Understand cast at 11 a.m. Eastern at [www.makino.com/events]. Each key elements that contribute to high performance, high webinar consists of a 20-45 minute presentation and a Q&A output five-axis machining to improve your part quality and session with the speaker. Registration is required to attend, maximize manufacturing output. but all webinars are presented free of charge. The schedule for the first quarter of 2008 is as follows: All Makino webinars are archived for later viewing at [makino. com/library]. There are over 60 webinars available on topics • Jan. 17—EDM for Aerospace, Part 2. Jeff Kiszonas, EDM such as micromachining, moldmaking, hardmilling, fixturing, Product Line Manager, will discuss recast layer, heat affect- tooling selection, and new webinars are added the week after ed zone (HAZ), micro cracking, and micro-hardness test they are broadcast. For more information call (800) 552-3288 results. This webinar, a continuation to the July 26, 2007 or visit [www.makino.com]. event, will briefly review that presentation and provide complete results of new testing by Makino and a NADCAP certified, independent laboratory. See how the Makino SP43 Wire SKF Specialty Coatings for Bearings Specialty coatings for SKF rolling bearings offer solutions to EDM performed in three different aerospace alloys. resist wear or to insulate against stray electric currents. Most bearing types can be coated to promote longer bearing life and • Jan. 24—Automated Five-Axis Machining. Automation and increased machinery uptime. five-axis machining continues to gain popularity due to their Promoting wear resistance, a patented NoWear® coating favorable impact on productivity and manufacturing cost applied on contact surfaces can withstand severe operating reduction. This seminar will illustrate how to combine both conditions due to sudden load and speed variations, poor technologies to achieve high productivity while also providing lubrication conditions from high temperature or low lubricant outstanding flexibility and ease of use. vicosities, vibration, smearing, and/or solid particle contamination. The coated bearings prove harder, exhibit less friction • Jan. 31—Surface Wizard Wire EDM Technology. The latest (and resulting heat) and can better tolerate potential damage advancement from Makino in Wire EDM control technology from contamination and/or marginal lubrication. Applications virtually eliminates witness lines in parts with variable and include compressors, pumps, fans and blowers, and gear- sudden changes in thickness or shape. boxes, among others. Offering insulating properties, INSOCOAT® rolling bearings • Feb. 14—Unique Solutions for Shaped Fine Hole Machining.

gearsolutionsonline.com • JANUARY 2008 • GEAR SOLUTIONS 43 protect against potential damage caused by the passage of Conicity’s EMG process results in longer tool life. AC or DC electric current. Applications include variable speed Conicity’s EMG technology is available to users through a motors, generators, and associated motor-driven equipment. variety of methods. Tools can be outsourced for processing Their thin aluminum oxide layer integrates the electrical to Conicity’s service center regardless of quantity. Tools that insulating function into the bearing to form a superior barrier have the EMG technology already applied are also available for against electric arcing and potentially damaging bearing ero- sale, and users can also obtain equipment licenses. sion. Coatings selected based on required resistance may be Conicity Technologies—a subsidiary of Weiler Corporation applied to either bearing bores or outside diameters, depend- headquartered in Cresco, Pennsylvania—is the developer ing on bearing size. of the patented EMG technology used to improve workpiece All coated bearing boundary dimensions conform to ISO and quality and extend tool life through precise management of ABMA standards and can easily replace non-insulated bearings the tool-workpiece interface. Contact the company at (877) without requiring design changes or rework prior to normal 752-6132 or visit online at [www.conicity.com]. mounting. Coated bearings are suitable for all types of shafts or housings and can be further customized to satisfy particular Flanged Linear Ball Bushings from application requirements. Misumi Contact SKF USA Inc., at (800) 440-4SKF or send e-mail to Misumi USA, Inc., offers round, square, and compact flange [email protected]. Go online to [www.skfusa.com]. style, single or double linear ball bushings for a variety of industrial applications. These products are available standard in 52100 bearing steel (with or without electroless nickel plated surface) or 440C stainless steel cylinder and ball construction, with resin or stainless steel retainers, Nitrile rubber seals and operating temperature ranges from –20ºC to +120ºC (~ -4ºF to +248ºF). These bearings feature tight tolerances on all critical dimensions, a necessity for handling shafts in continuous operation or rugged environments. Misumi flanged linear ball bushings accept shaft diameters from 6mm to 50mm and easily surface mount through four predrilled holes in the flange. Depending upon the size a two- hole or four-hole style is offered in the compact flange design. New self-lubricating styles, as well as low dust raise greased for cleanrooms and seal-less styles are also being offered by Misumi for applications requiring such components. The self- lubricating bearings offer low maintenance and 3x longer rated life span than conventional linear bearings. Details are available at [www.misumiusa.com].

Conicity Offers Online Help with Cutting Tool Edge Preparation Conicity Technologies, the world leader in cutting tool edge preparation technology, has an informative, user-friendly Web site, listed below. The site contains a wealth of informative material including an introduction to edge preparation, case studies, lab evaluations, an edge prep image library, edge preparation equipment and supplies available for purchase and technical information on Conicity’s patented Engineered Micro-Geometry™ (EMG™) process. EMG technology distributes a precise micro-geometry along the cutting edge to dramatically improve the performance of nearly all carbide, cermet, ceramic, CBN, and PCD tools. Previously, controlling the hone on the edge of a tool was impossible to carefully engineer; Conicity’s patented EMG makes this possible. The Web site highlights the key benefits to using EMG technology, which include increased productivity by enabling the tool to withstand higher cutting forces and operating at higher speeds without breakage. Part quality is also improved due to the production of precise surface finishes. In addition,

44 GEAR SOLUTIONS • JANUARY 2008 • gearsolutionsonline.com Contact Gear Solutions at MACHINERY 800-366-2185 to list your machinery.

BARBER-COLMAN 2 1/2-2, S/N 16, ’66 Wet w/Auto Feed REF#104 PFAUTER #P-900, 2 DP, 36” Dia, 15” Face, Tailstock, ‘60 REF#103 featuredSuppliers: BARBER-COLMAN 6-5, S/N 110R, ’55 Wet w/Auto Dress & Sparkout REF#104 RPM #AD-616, 6” Dia, 16” Face, 16 DP, (3) Thread, NEW REF#103 BARBER-COLMAN 6-5, S/N 396, ’66 Wet w/Auto Dress & Sparkout REF#104 STANKO #5A-342, 100-160” Dia, 34” Face, .84 DP, Beautiful Piece, ‘80 REF#103 Midwest Gear Corporation — Ref #100 BARBER-COLMAN 6-5, S/N 433, ’69 Wet w/Auto Dress & Sparkout REF#104 WOLF #GH20-11, 20” Dia, 11” Face, 3.2 DP, ‘98 REF#103 Phone: 330-425-4419 • Fax: 330-425-8600 Email: [email protected] BARBER-COLMAN 10-12, S/N 643R83, Wet w/Auto Dress, PC WOLF #GH32-11, 32” Dia, 11” Face, 2.5 DP, ‘98 REF#103 Website: www.mwgear.com Control, Fact Reb ‘83 REF#104 BARBER-COLMAN 2 1/2 -4, S/N 119, ’62 Hi-Production Spur Gear REF#104 BARBER-COLMAN 6-10 SYKES, Triple Thrd w/Lever Operated Collet Assy REF#104 GEAR HOBBERS/CUTTERS Mohawk Machinery, Inc. — Ref #101 BARBER-COLMAN 6-10 B&C Ltd, S/N 8079, Triple Thrd REF#104 Phone: 800-543-7696 • Fax: 513-771-5120 KOEPFER #150, 6” Dia, Refurbished w/Accessories REF#101 BARBER-COLMAN 6-10, S/N 4626, ’57 Triple Thrd 3” Hob Slide REF#104 Email: [email protected] Website: www.mohawkmachinery.com KOPEFER #151, 6” Dia, Refurbished w/Accessories REF#101 BARBER-COLMAN 6-10, S/N 4659R, ’56 Triple Thrd Adj Ctr Assy REF#104 KOPEFER # 170, 5.1” Dia, Refurbished, w/Accessories REF#101 BARBER-COLMAN 6-10, S/N 4665, ’57 Fine Pitch Prec Triple Thrd REF#104 New England Gear — Ref #102 PFAUTER #RS00S, 8”/10” Dia, 6 DP, Diff REF#101 BARBER-COLMAN 6-10, S/N 4701, ’58 Triple Thrd w/Power Down Feed REF#104 Phone: 860-223-7778 • Fax #:860-223-7776 LIEBHERR #L-301, 12” Dia, 2-Cut, Crowning REF#101 BARBER-COLMAN 6-10 M/C, S/N 4755, ’59 Triple Thrd w/MC Conversion REF#104 Email: [email protected] Website: www.newenglandgear.com CLEVELAND #CR-300, 12” Dia, Crowning, 2-Cut, New REF#101 BARBER-COLMAN 6-10 Multicycle, S/N 4778R87, ’60 (’87 Rebuild), PFAUTER # P-400, 16” Dia, Vertical Universal, High Tailstock REF#101 Sgl Thrd Hi-Spd REF#104 R. P. Machine Enterprises, Inc. — Ref #103 PFAUTER #P-403, 18” Dia, Auto-2-Cut, New ’79 REF#101 BARBER-COLMAN 6-10 M/C, S/N 4913, ’63 Triple Thrd w/90 Deg Hob Slide REF#104 Phone: 704-872-8888 • Fax #:704-872-5777 LIEBHERR #L-901, 36” Dia, Crowning, Auto-2-Cut, Diff, Yr ’74 REF#101 BARBER-COLMAN 6-10 Multicycle, S/N 5055, ’66 Triple Thrd, 800 RPM REF#104 Email: [email protected] Website: www.rpmachine.com G&E #96H, 100” Dia, 1 DP, Crowning, New ’72 REF#101 BARBER-COLMAN 6-10, S/N 5141, ’67 Triple Thrd w/Prec Hob Shift REF#104 BARBER COLMAN #3, 6” Dia REF#101 BARBER-COLMAN 6-10 Multicycle, S/N 5148, ’68 Triple Thrd, 800 RPM REF#104 Repair Parts, Inc. — Ref #104 BARBER COLMAN #16-16, 16” Dia REF#101 BARBER-COLMAN 6-10 Multicycle, S/N 5259, ’75 Triple Thrd w/Auto Hob Shift REF#104 Phone: 815-968-4499 • Fax #:815-968-4694 BARBER COLMAN #14-15, 14” Dia, Series A-2, Shift, 2-Start REF#101 BARBER-COLMAN 6-10, S/N 5353, ’77 Triple Thrd w/3” Hob Slide, 800 RPM REF#104 Email: [email protected] BARBER COLMAN #14-15, 14” Dia, 4-Start Index, Chucking REF#101 BARBER-COLMAN 6-10, S/N 5394, ’81 Fine Pitch Triple Thrd w/Dwell & Hob Rev REF#104 Website: www.repair-parts-inc.com BARBER COLMAN #16-36, 16” Dia, w/Differential REF#101 BARBER-COLMAN 6-16 M/C, S/N 5238, ’70 Triple Thrd, Recon ‘02 REF#104 Broaching Machine Specialties — Ref #105 BARBER COLMAN “Multi-Cycle” #16-36, 16” Dia, w/shift C-Frame REF#101 BARBER-COLMAN 6-10, S/N 5407, ’82 Auto w/PLC Control REF#104 Phone: 248-471-4500 • Fax: 248-471-0745 TOS OF-16, 60” Dia, Auxiliary Work-table, Change Gears REF#101 BARBER-COLMAN DHM, S/N 105, ’42 Double Thrd REF#104 Email: [email protected] BARBER-COLMAN #14-15, 14” Dia, 15” Face, 1 to 4 Start Worm, Several REF#103 BARBER-COLMAN 14-15, S/N 635R, ’53 Dbl Thrd, Fact Reb REF#104 Website: www.broachingmachine.com BARBER-COLMAN #14-30, 14” Axis, 30” Dia, 3.5 DP REF#103 BARBER-COLMAN 14-15, S/N 745, ’55 Dbl Thrd w/Dwell REF#104 BARBER-COLMAN #16-16, Multi-Cycle, Dual Thread Worm, Downfeed REF#103 BARBER-COLMAN 14-15 Dual Fd, S/N 938, ’62 Dbl Thrd, Comp Reco REF#104 GEAR ACCESSORIES, PARTS & TOOLING BARBER-COLMAN #16-36, 24” Dia, C-Frame Style, 4 1/8” Bore REF#103 BARBER-COLMAN 14-15, S/N 1055, ’65 Dbl Thrd w/New Hyd Sys REF#104 REF#103 REF#104 FELLOWS Model #10-4/10-2, All Parts Available REF#102 BARBER-COLMAN #16-56, 16” Dia, 56” Face, Differential BARBER-COLMAN 14-15, S/N 1131, ’66 Dbl Thrd w/Hyd Tailctr REF#103 REF#104 Tilt Tables for 10-2/10-4, Qty 2 REF#102 BARBER-COLMAN #2.5-4, 2.5” Dia, 2.25” Face, Precision Machine BARBER-COLMAN 14-15 Dual Fd, S/N 1261, ’67 Dbl Thrd w/Hyd Live Ctr BARBER-COLMAN #22-15, 22” Dia, 14” Face, Differential REF#103 BARBER-COLMAN 14-15 Dbl Cut, S/N 1278, ’68 Dbl Thrd w/4-1/8” Bore REF#104 GEAR HOBBERS/CUTTERS CNC BARBER-COLMAN #3 (6-10), Single & Triple Tread Worm Ref # Several REF#103 BARBER-COLMAN 14-30 Dual Fd, S/N 1371, ’71 4-Thrd w/Sizing Cycle REF#104

BARBER-COLMAN #6-16, 6 Start Worm, Downfeed, Hyd. Clamping REF#103 BARBER-COLMAN 22-15, S/N 923, ’62 Dbl Thrd, Dbl Cut REF#104 PFAUTER #PE-150, 6” Dia, 6-Axis CNC, New ‘86 REF#101 G&E #24H Universal Head, Infeed, Tailstock, Differential, ‘50’s REF#103 BARBER-COLMAN 16-11, S/N 184, ’50 Dbl Thrd w/Vert DRO REF#104 LIEBHERR #LC-152, 6”/8” Dia, 7-Axis CNC w/Automation, New ’90 REF#101 G&E #36HWD, Differential, Excellent Condition REF#103 BARBER-COLMAN AHM, S/N 1896, ’42 Sgl Thrd w/3 Jaw Chuck REF#104 PFAUTER #PA-320, 14” Dia, 6-Axis, Rebuilt/Retrofit ’06 REF#101 G&E #48HWD, Differential, Excellent Condition REF#103 BARBER-COLMAN 16-16, S/N 2745, ’51 Sgl Thrd w/90 Deg Hd REF#104 G&E #96H, 100” Dia, .75 DP, CNC Universal REF#101 G&E #72H, 72" Dia, 1.5 DP, 24" Face, Diff, Infeed REF#103 BARBER-COLMAN 16-16, S/N 3171, ’53 Dbl Thrd, Spanish Nameplates REF#104 G&E #96H, CNC, Gasher/Hobber, New ‘05 REF#103 G&E #96H, High Stanchion, Differential, Infeed REF#103 BARBER-COLMAN 16-16, S/N 3580, ’59 Dbl Thrd w/Diff & Auto Hobshift REF#104 G&E #120H, CNC, Gasher/Hobber, Twin Stanchion, 1/2 DP, 42” Face, ‘94 REF#103 HAMAI #120, 4.8” Dia, 4” Face, 12 DP, ‘70 REF#103 BARBER-COLMAN 16-16 Multicycle, S/N 3641, ’60 Dbl Thrd w/Diff REF#104 G&E #160H, CNC, Gasher/Hobber, New ‘05 REF#103 KOEPFER #135, Horiz, Loader, 3” Dia, 3” Face, 25 DP, ‘60 REF#103 BARBER-COLMAN 16-16, S/N 3660, ’57 Sgl Thrd REF#104 GLEASON PHOENIX #200GH, 6-Axis CNC, 7.87" Dia, 7.8 DP REF#103 LIEBHERR #L-301, 12” Dia, 9’ Face, 4 DP, ‘74 REF#103 BARBER-COLMAN 16-16, S/N 4136, Dbl Thrd, “C” Style End Brace w/Diff REF#104 HAMAI 60H, CNC 4-Axis, 3.5" OD, 9" Face, 12 DP, New ‘89 REF#103 LIEBHERR #L-401, 16” Dia, 8’ Face, 3 DP, ‘70’s REF#103 BARBER-COLMAN 16-16 Multicycle, S/N 4170, Dbl Thrd w/Jump Cut Cycle “C” Style REF#104 LIEBHERR #LC-252 CNC, 6-Axis, 10” Dia, 10” Face, 4 DP, ‘77 REF#103 LIEBHERR #L-402, 16” Cap, 2-Cut Cycle, Crowning, ‘77 REF#103 BARBER-COLMAN 16-16, S/N 4473, ’73 4-Thrd w/Workclamp Cyl “C” Style REF#104 LIEBHERR #LC-255 CNC, 6-Axis, 10” Dia, 10” Face, 4 DP, ‘87 REF#103 LIEBHERR #L-650, 26" Dia Cap, 14.5" Face, 2.5 DP, New ‘70’s REF#103 BARBER-COLMAN 16-16 Multicycle, S/N 4520, ’75 Dbl Thrd w/Gooseneck Slide REF#104 LIEBHERR #L-1202 6-Axis CNC, 49” Dia, 24” Face, 1.2 DP, ‘78 REF#103 LIEBHERR #L-652, 25" Dia Cap, 19.7" Face, 2 DP, Well-Equipped REF#103 BARBER-COLMAN 16-16 Multicycle, S/N 4631, ’79 “C” Style End Brace, 4W Adj Ctr REF#104 MITSUBISHI #GA-40, 5-Axis, 16” Dia, 10” Face, w/Fanuc, ‘86 REF#103 LIEBHERR #L-901, 35" Dia, 2.5 DP, 2-Cut Cycle, Univ Hob Head REF#103 BARBER-COLMAN AHM (36”), S/N 1152, ’42 Dbl Thrd REF#104 PFAUTER #P-250H, 6-Axis, 11.81” Dia, Fanuc O Control, New ‘85 REF#103 LIEBHERR #L-902, 36" Dia, 25" Face, 2 DP, Crowning, ‘78 REF#103 BARBER-COLMAN 16-36, S/N 4090, ’66 Dbl Thrd, “C” Style End Brace REF#104 PFAUTER #PE-125H, 6-Axis, 5" Dia, 8.5 DP, 9.5" Max Swing, ‘88 REF#103 MODUL #ZFZW 800, 29.8” Dia, 16.25” Face, 2.5 DP Crowing, 2-Cut REF#103 BARBER-COLMAN 16-36 Multicycle, S/N 4232, ’68 Dbl Thrd “C” Style End Brace w/Diff REF#104 PFAUTER #PE-150, 6-Axis CNC, 6” Dia, 5 DP, 6” Face, Fanuc 18MI REF#103 OVERTON #HD-400, 15.7” Dia, 12” Face, 3 DP, New ‘88 REF#103 BARBER-COLMAN 16-56, S/N 3136R84, ’53 (Reb ’84), Dbl Thrd REF#104 PFAUTER #PA-320, 6-Axis CNC, 13” Dia, 3 DP, 10” Face, New ‘80 REF#103 PFAUTER #P-400, 3 DP, 16" Dia, 11" Face, Auto-Cycle, ‘65 REF#103 BARBER-COLMAN 10-20, S/N 6700045890, ’76 Dbl Thrd w/2 Cut Cycle REF#104 PFAUTER #PE-500, 6-Axis CNC Gear Hobber, 13.78" Dia, 3 DP REF#103 PFAUTER #P-630, 24” Cap, 2-Cut Cycle, Crowning, ‘78 REF#103 RP MACHINE #SH-150/750, 4-Axis CNC Spline Hobber, New ‘05 REF#103 PFAUTER #P-750R, 8" Dia Rotors, 35" Face, 12", MINT!! ‘82 REF#103 SYKES #H160, 4-Axis CNC Hobber, 6” Dia, All the Features, ‘93 REF#103 gearsolutionsonline.com • JANUARY 2008 • GEAR SOLUTIONS 45 FELLOWS #20-4, 20” Dia, 4” Face, 4 DP, ‘70’s REF#103 GEAR PINION HOBBERS & SPLINE MILLERS GEAR GRINDERS CNC FELLOWS #36-6, 36” Dia, 6” Face, 3 DP, ‘51-‘72 REF#103 DAVID BROWN, #P-40H, 40” Dia, 100” Face, 2 DP, New ‘70 REF#103 FELLOWS #120-8, 8” Stroke, Spur Guide, Rebuilt 1988, New Electrics REF#103 HOEFLER #H-650/800, 36” Dia, CNC w/On-Board Inspection, New ‘98 REF#101 FITCHBURG, 40” Dia, 73” Face REF#103 FELLOWS #200, 8” Stroke, 200” Dia Spur, Exc. Cond 1 DP, Rebuilt ‘88 REF#103 GLEASON # 130, 36” Max Dia, CNC Curvic Cplg, Comp Reb REF#101 LEES BRADNER #SH, 8” Dia, 54” Face, 4 DP, ‘50 REF#103 FELLOWS #Horiz Z Shaper, 6” Stroke, 17” Bore in Table, New ’50’s REF#103 HOFLER/NOVA, #650/800, 25” Dia, 21” Face, 1.4 DP, New ‘98 REF#103 HURTH #KF-32A 15” Dia, 59” Face, ‘67 REF#103 LORENZ #LS-320, Tilt Shaper, 12” Dia, 2” Face, 4 DP, New ‘80’s REF#103 OPAL #50 CNC Form Grinder, 20.5" Dia, 24.8" Face, ‘98 REF#103 WANDERER #31M, 12” Dia, 118” Length, Hob Head Equipped REF#103 LORENZ #LS-320, 12” Dia, 2” Face, 4 DP, New ‘88 REF#103 OPAL #420 CNC Form Grinder, 16” Dia, 14” Face, 2 DP, New ‘93 REF#103 MAAG #SH-75C, Disc Control, 9” Stroke, Auto Stop, Exc, ‘65 REF#103 OPAL #1200 CNC Form Grinder, 47” Dia, 25” Face, 1.5 DP, ‘97 REF#103 GEAR HOB & CUTTER SHARPENERS (incl CNC) MAAG #SH-100/140, 57” Dia., 12.6” Face, 2 DP, Internal Attachment REISHAUER #RZ-801, 31” Dia, 11” Face, 3.5 DP, New ‘91 REF#103 REF#103 BARBER COLMAN #2 1/2-2, 2.5” Dia, Straight Flute Hobs REF#101 GEAR GRINDERS FELLOWS 6HCS, 6” Dia, Helical Shaper Cutter Sharpener REF#101 MAAG #SH-180/300, Ext. Generating/Int Gashing Heads, New ‘60’s REF#103 GLEASON 2JST Straight Bevel “Coniflex” Cutter Sharpener REF#101 MAAG #SH-250, 43” Dia., 26” Face, Crowning, New ‘74 REF#103 MAAG #HSS-30A, 11.8” Dia, Spur REF#101 GLEASON 13 Universal Hypoid Bevel Cutter Sharpener REF#101 REISHAUER #AZA-K, 13” Dia, SPA Diamond Disc, Taper Grinding New ’79 REF#101 GEAR DEBURRING/CHAMFERING/POINTING ARTER #A-12, 12” Rotary Surface Grinder for Sharpening Sharper Cutters REF#103 REISHAUER RZ-300E, 11.8” Dia, Diamond Disc Dresser, Shift – New ‘85 REF#101 BARBER-COLMAN #6-5, 6" Dia, 5" Length, Manual Dresser, ‘57 REF#103 CROSS #75, 10” Dia REF#101 SHG-360 OKAMOTO, 14” Dia, FAESSLER DSA, Crowning, New ’74 REF#101 BARBER-COLMAN 10-12, 10" Dia, 12" Length, Spark Out REF#103 REDIN #24, 28” Dia, CNC, Twin Spindle Deburring Mach, Yr ’90 REF#101 DETROIT GEARGRIND GGI-16x3A Internal Gear Grinder REF#101 FELLOWS #6SB, Helical Cutter Sharpener, 6” Dia, up to 50 Degrees REF#103 REDIN #18, 20” Dia, Twin Spindle Deburring Mach REF#101 MICHIGAN DETROIT GG-10x24A, 10” Dia, Ext Gear & Spline Grinder REF#101 HEALD #22 Rotary, 13” Dia, 12” Chuck REF#103 CROSS #50 Gear Tooth Chamferer, 18” Dia, Single Spindle REF#103 FELLOWS-REISHAUER #12, 12" OD, 6-3/4" Face, Dresser, Gears REF#103 KAPP #AS204GT, 10” Dia, Wet Grinding, CBN Wheels, ‘82 REF#103 CROSS #54 Gear Tooth Chamferer, 30” Dia, 18” Face REF#103 HOFLER H2500/1200, 98” Dia, 47” Face, 8DP, ‘74, ISO 3-4 Quality REF#103 KAPP #AS-305T, 12” Dia, 28” Face, 1 DP, Mint Condition, New ‘80’s REF#103 CROSS #55 Gear Tooth Chamferer, 18” Dia, 14” Face REF#103 REISHAUER ZA, Gear Grinder, 13" Dia, 6" Face, Strait & Helix REF#103 KLINGELNBERG #AGW-30A, 11” Dia, 16” Part Length, Straight & Spiral Gash REF#103 CROSS #75 Gear Tooth Chamferer, 10” Dia, 10” Face, ‘52 REF#103 REISHAUER #AZA & #AZA-K, 11” Dia, 3 DP, 7” Face, Exc Cond REF#103 KLINGELNBERG #AGW-231, Auto Hob Sharpener, 10" Dia, ‘74-80 REF#103 HURTH #ZK-7, 11” Max Dia, Twin Spindle Gear Chamferer REF#103 REISHAUER ZB Gear Grinder, 27 5” Max Dia, 11” Face, Good Cond ‘70 REF#103 RED RING #GCU-12, Gear Shaver, 12” Dia, Several REF#103 RED RING #SF-500 Int/Ext, 26” Dia, 30” Face, 2 DP, ’88 REF#103 GEAR SHAPERS CNC RED RING #GCY-18, Gear Honing Mach, 18” Dia, 6” Stroke REF#103 RED RING #SGJ-18, 18” Dia., 9” Face, Internal Attachment, New ‘78 36” Shapers, 14” Throat Risers, 53” of Swing, Qty 3 REF#102 RED RING #GCX-24, 3”-24” Pitch Dia Crowning, Tailstock, Taper Att REF#103 REF#103 FELLOWS #10-4/10-2, Qty 150 REF#102 REDIN #18, 28” Dia, 2, 3, 4 Spindle, Deburrer/Chamfer, PLC’s, Tilt Table REF#103 GEAR RACK MILLERS/SHAPERS HYDROSTROKE #50-8, Qty 2 REF#102 REDIN #20D, 20” Dia, Twin Spindle, Deburrer/Chamfer REF#103 HYDROSTROKE #20-8, Qty 5 REF#102 SAMPUTENSILI #SCT-3, Chamf/Deburrer, 14” Dia, 5” Face, ‘82 REF#103 FELLOWS #3X36 Rack Shaper, 3” Face, 36” Face, 4 DP, Good Cond ‘60 REF#103 HYDROSTROKE #FS630-125, Qty 1 REF#102 SAMPUTENSILI #SM2TA Gear Chamfering Mach, 10” Max Dia, (3) New ‘96 REF#103 MIKRON #134 Rack Shaper, 17.4" Length, 1.1" Width, 16.9 DP REF#103 HYDROSTROKE #FS400-90, Qty 2 REF#102 WERA #MC6-150, CNC, Deburrer, Chamfering and Pointing, 8” Dia, New ‘88 REF#103 SYKES VR-72 Vert Rack Shaper, 72" Cut Length, 4DP, 4" Stroke, ‘80 REF#103

FELLOWS #20-4, Qty 6 REF#102 GEAR HONERS GEAR THREAD & WORM, MILLERS/GRINDERS FELLOWS #48-8Z, Qty 1 REF#102 FELLOWS #10-2 & 10-4, 1 to 4-Axis CNC, 10” Dia, 2”-4” Face, Rebuilt REF#103 FASSLER #K-400 Internal Gear Honer, 12.6” Dia, 12” Stroke, NUM 1080 Control WMW HECKERT #ZFWVG, 10” Dia, 49” Length, 4, ’99 REF#103 FELLOWS #10-4 One-Axis CNC (A/B), 10" Dia, 4" Face, 4 DP REF#103 REF#103 WMW HECKERT #ZFWG 250 X 2000, 19.6” Over Bed, 19.6” 78.7” Hob Length FELLOWS #20-4, 4-Axis, 20” Int/Ext, Dia, 4” Face, New ‘70/’03 REF#103 REF#103 GEAR SHAVERS FELLOWS #20-8, Hydrostroke 6-Axis CNC, 20" Dia, 8" Face, 3 DP REF#103 LEES BRADNER #HT 12"x 36" Thread Mill, 12" Dia, 36" Length REF#103 FELLOWS #FS-180, 3-5 Axis, 7” Dia, 1.25” Face., 6 DP, New ‘88 REF#103 RED RING #GCY-12, 12” Dia, 9” Cutter-Head REF#101 LEES BRADNER #LT 9"x 54" Thread Mill, 9" Dia, 54"Length REF#103 FELLOWS #FS-630-200, 6-Axis, 24” Dia, 8” Face, 3 DP, ‘95 REF#103 RED RING #GCU-12”, 12” Dia, 9” Cutter-Head REF#101 MIKRON #106-02, 1.5” Dia, 3-6” Length, Single Form Worm Cutter REF#103 LIEBHERR #WS-1, 4-Axis CNC, 8" OD, 2" Stroke, Fanuc 18MI REF#103 KANZAKI #GSF-400CNC5, CNC, 16” Dia, 10” Cutter-Head ‘90 REF#101 J&L #12x45, Thread Grinder, 12” OD, 45” Length, Nice, ‘75 REF#103 LORENZ # LS-180, 4-Axis CNC, 11” OD, 2” Stroke, 5 DP REF#103 RED RING #GCU-18, 18” Dia, Crowning REF#101 REISHAUER #UL-900, 9” Dia, 18” Grinding Length, ‘80’s REF#103 LORENZ #LS-424, 16.5" Max Dia, 5.4" Stroke, ‘90’s REF#103 RED RING #GCJ-36/60, 60” Dia, 12” Cutter-Head REF#101 REISHAUER #US, 10” Dia, 36” Grinding Length, 46” B-C, ‘80 REF#103 WANDERER #31L x 3000, 8” Dia, 120” Length, ‘60’s REF#103 GEAR SHAPERS GEAR GENERATORS, STRAIGHT BEVEL GEAR TESTERS/CHECKERS (incl CNC) FELLOWS #3, 3” Dia, Fine Pitch, w/Change Gears REF#101 GLEASON #710, 10” Dia, Coniflex REF#101 FELLOWS #7125A, 7” Dia REF#101 GLEASON #14, 24” Dia, Coniflex w/gauges, gears REF#101 GLEASON 13, Universal Angular Bevel Tester REF#101 FELLOWS #4AGS, 7” Dia REF#101 OERLIKON #K4A, 60”/90” Dia w/Templates, Crowning, Gears REF#101 GLEASON #17A, 90-Degree Hypoid Bevel Tester REF#101 FELLOWS #10-4, 10” Dia, 4” Face REF#101 GLEASON #12, Str Bev Gear Gen, 12” Cone, 3.5 Face, ‘50’s REF#103 FELLOWS #12M, 12” Dia, Involute REF#101 FELLOWS #10-2, 10”Dia, 2” Face REF#101 GLEASON #14 Coniflex Str Bev Gear Gen, 12” Max Cone Dist, 3.5” Face REF#103 FELLOWS 600RL, 24” Dia, Roll Checker REF#101 FELLOWS Z-Type Horizontal, 18” Dia, Change Gears, Nice REF#101 GLEASON #16 Hypoid Gear Gen, 9” Max Cone Dist, 2.75” Face REF#103 Please Check Our Website to View the Gear Testers and Recorders in Our FELLOWS #36-6, 40” Dia, 6” Face, 6” Riser REF#101 GLEASON #114 Coniflex Str Bev Gear Gen, 7” Max Cone Dist, 2.5” Face REF#103 Inventory REF#103 FELLOWS #36-6 Spur/Helical, 36” Dia, 6” Face, w/Vari Helix Head REF#101 GLEASON #24A Coniflex, 1.5 DP, 6" Face, 6" Work Spindle Bore REF#103 MISCELLANEOUS FELLOWS 100” Dia, 8” Face-Width, Change Gears, Extra Guide, Gears REF#101 MIKRON #120.1 & 132.02, 1.6” Dia, 25 DP, 50’s-60’s REF#103 FELLOWS #10-2, (10” Dia), 2” Face REF#102 WARNER & SWAYSEY #4A M-3580 Turret Lathe, 28 1/4 Swing, 80” Centers, GEAR GENERATORS, SPIRAL BEVEL (HYPOID) FELLOWS #10-4, (10” Dia), 4” Face REF#102 12” Spindle Hole 50/25 Motors, 480/3 Phase, Year 1965 REF#100 BARBER COLMAN #10 VGS, 10” Dia, 4” Face, 4 DP, New ‘81 REF#103 GLEASON #16, 16” Dia Hypoid Spiral Bevel Gear Generator REF#101 GEAR BROACHING MACHINES FELLOWS #3-3 & #3-1, 3” Max Dia, 1” Face, Pinion Supp, High Precision REF#103 GLEASON #26, 36” Dia, Hypoid Spiral Bevel Gear Generator REF#101 FELLOWS #4A Versa, 10” Dia, 3” Face, 4 DP, New ‘70’s REF#103 Broach, Vertical Internal Table-Up -- 15 Ton, 54” Stroke – BMS, will tool REF#105 Broach, Vertical Internal Table-Up -- 10 Ton, 42” Stroke – BMS, will tool REF#105 FELLOWS #4A & 4AGS, 6” Dia, 2” Face, 4DP, ’68, Ref.# Several REF#103 GEAR GENERATORS, HERRINGBONE Broach, Vertical Pull-Down -- 10 Ton, 36” Stroke – American, with feed table REF#105 FELLOWS #4AGS, 6” Dia, 2” Face, 4DP, Tilt Head Machine REF#103 Broach, Vertical Pull-Down -- 25 Ton, 72” Stroke – Colonial, excellent, BMS will tool REF#105 FELLOWS #61, #6A, #61A, #645A, From 18”-35” Dia, 0-12” Risers REF#103 SYKES #1A, 12” Dia, 30˚ Guide and Spur Guide REF#103 Broach, Horizontal -- 10 Ton, 60” Stroke – Lapointe, rebuilt, excellent REF#105 REF#103 REF#103 FELLOWS #7, #7A, #715 Etc, 7” Dia, 0-12” Risers, Several Avail SYKES #5B, 60” Dia, 30˚ Guide 8” Face, New ‘60’s Broach, Horizontal -- 15 Ton, 66” Stroke – Lapointe, BMS will tool REF#105 FELLOWS #8AGS Vert Gear Shaper, 8” Dia, 2” Face, 6-7 DP REF#103 FARREL #5B, 61” Dia, 30˚ Guide, 18” Face, New ‘50’s REF#103 Broach, Horizontal -- 35 Ton, 90” Stroke – Detroit, complete REF#105 FELLOWS #10-2, 10” Dia, 4” Face, 4 DP REF#103 FARREL #5T, 61” Dia, 30˚ Guide, 24” Face, 2 DP REF#103 Broach, Horizontal -- 6 Ton, 48” Stroke – Oilgear REF#105 FELLOWS #10-4, 10” Dia, 4” Face, 4DP REF#103 Broach, Horizontal -- 3 Ton, 30” Stroke – Lapointe REF#105

46 GEAR SOLUTIONS • JANUARY 2008 • gearsolutionsonline.com

Contact Gear Solutions at 800-366-2185 MARKETPLACE to feature your business in the Marketplace!

Manufacturing excellence through quality, integration, materials, maintenance, education and speed.

PRECISION GROUND SPIRAL BEVEL GEARS SPUR / HELICAL GEARS • WORMS • STRAIGHT BEVEL GEARS WORM GEARS • GROUND RACKS Due to customer demands, we have expanded our Straight bevel ability and added Spiral BevelS to our capabilities. Our capacities are constantly expanding, so please forward your specific requirements PROTOTYPE OR PRODUCTION for a prompt, competitive quotation.

MAKE COMPLETE OR SPIRAL BEVEL .25” to 33” Diameter OPERATIONAL INCLUDING: 32 DP to 2 DP .5 Module to 12 Module

GEAR BOXES & ASSEMBLY • GEAR STRAIGHT BEVEL .25” to 36” Diameter PUMPS • AEROSPACE • MILITARY • 32 DP to 1.5 DP .5 Module to 16 Module COMMERCIAL • HOBBING • SHAPING • Manufacturing all types of custom gears: TURNING • JIG GRINDING Spiral Bevels, Straight Bevels, Spurs, Helicals, Worm and Worm Gears, Herringbones, Racks, • M&M GEAR INSPECTION • Splines, Internal Gears, Sprockets, Ratchets NITAL ETCH • MAGNAFLUX Tooth Cutting, Grinding & Shaving services available.

Please fax your inquiries Quality Custom to Dennis Garthus at 24649 Mound Road • Warren, MI 48091 708-652-1100 Gearing Since 1951 Phone (586) 754-4600 • Fax (586) 754-4603 Email: [email protected] CIRCLE GEAR and MACHINE 1501 South 55th Ct. • Cicero, IL 60804 • Ph: 708-652-1000 • Fax: 708-652-1100 • circlegear.com

CNC Service Technicians

Reishauer Corporation, located in Elgin IL, is currently seeking experienced CNC Service Technicians. Join our highly trained and diverse team! Qualified technicians will be trained to provide service to our customers in the United States, Mexico and Canada, with services including:

• Installation, commissioning & demonstration of new Reishauer gear grinding machinery at manufacturing plants. • Active support of customer personnel in the application of new machinery. • Training of customer machine operators & maintenance personnel. • Assistance during maintenance & repair of machinery. • Assistance during machine exchanges or retooling. • Assistance during grinding trials on newly installed machinery at manufacturing plants.

Reishauer Corporation offers an exceptional full-time benefits package! • Competitive wages based on experience. • PPO Health & Dental Insurance. Interested individuals should • Paid Life Insurance. submit resume and salary • 401k Retirement Plan requirements to: • Paid Vacations and Holidays Reishauer Corporation, 1525 Holmes Road, Elgin, IL 60123 Fax: 847 / 888-0343 Email: [email protected]

48 GEAR SOLUTIONS • JANUARY 2008 • gearsolutionsonline.com GEAR GRINDING SERVICES INNOVATIVE HOB SHARPENING (763) 425-5247 Gear cutting from raw material to RACK & GEAR finished parts COMPANY ★ THIN FILM COATINGS ★ Ground tooth gears and pinions HSS & Carbide up to 5” Dia. to 1 D.P. and up to AGMA quality Straight Gash, class 13 Sharpened & Inspected Per AGMA STANDARDS Quick Turnaround From 1” Diameter, 64 D.P. to maximum sizes listed Max. Face Max. Size Max. Pitch Spur Gears 24” 92” P.D. 1 D.P. Helical Gears 24” 72” P.D. 1 D.P. Spur & Helical Gears, Crown Hobbed 22” 72” P.D. 1 D.P. Internal Gears & Splines 8” 100” P.D. 1-1/4 D.P. Ground Gears, Crowned or Straight 20.5” 72” P.D. 1 D.P. Herringbone Gears, Center Grove 14” 36” P.D. 2 D.P. KORO SHARPENING SERVICE 9530 85th AVENUE NORTH 2182 E. Aurora Rd., Twinsburg, OH 44087 MAPLE GROVE, MN 55369 797 Eagle Drive • Bensenville, IL 60106 Phone: (330) 425-4419 • Fax: (330) 425-8600 [email protected] www.mwgear.com • E-mail: [email protected] 630-766-2652 • fax 630-766-3245 • www.gearacks.com LAWLER GEAR CORP. LEE’S SUMMIT, MISSOURI

Gear Manufacturing (from singles to production & reverse-engineering services) SPUR - HELICAL - SPLINE - WORM - BEVEL - RACK Gear Hobbing • Gear Shaping • Gear Rack • Sprockets Broaching • CNC Turning • CNC Milling • Automatic Sawing

A HANDFUL OR A TRUCKLOAD!

STOR-LOC MODULAR DRAWER SYSTEM LAWLER GEAR CORP. 880 N. Washington Ave. Kankakee, IL 60901 1320 S.E. Hamblen Road • Lee’s Summit, MO 64081 Toll Free: 1.800.786.7562 • Fax: 1.800.315.8769 Toll Free: 800-346-3038 email: [email protected] Missouri: 816-525-0002 • Fax: 816-525-1113 www.storloc.com

(248)(248) 601-8145601-8145 FAX (248) 601-0505 Email:Email: [email protected]@colemfgsystems.com www.colemfgsystems.comwww.colemfgsystems.com

gearsolutionsonline.com • JANUARY 2008 • GEAR SOLUTIONS 49 advertiserINDEX COMPANY NAME PAGE NO.

Abundant Manufacturing Inc...... 48 Aero Gear Inc...... 31 Allen Adams Shaper Services...... 48 Allied Sinterings Inc ...... 28 Bourn & Koch ...... 51 BuyPass Dealer...... 47 C-B Gear & Machine Inc...... 24 Cincinnati Gearing Systems ...... 33 Circle Gear & Machine Co...... 48 Clifford Jacobs Forging Co...... 23 Cole Manufacturing Systems Inc...... 49 Encoder Products ...... 41 First Gear...... 30 Gear Motions...... 24 Gear Solutions Online...... 50 Gleason Corporation...... IFC Hanik Corporation...... 51 High Performance Gear...... 2 Innovative Rack & Gear ...... 49 KAPP Technologies...... 1 KISSsoft USA LLC...... 34 Kleiss Gears ...... 49 Klingelnberg GmbH...... 9 Koro Sharpening Service...... 49 Larson Forgings...... 31 Lawler Gear Corp...... 49 Machinetools.com...... 49 Midwest Gear Corp...... 49 Mitsubishi Gear Tech Center...... BC Mohawk Machinery...... 10 Nachi America Inc...... 4 National Bronze & Metals Inc...... 33 New England Gear...... 7 Process Equipment...... 2 R.P. Machine Enterprises Inc...... 3,13,21 Raycar Gear & Machine...... 34 Reishauer ...... 48 Repair Parts Inc ...... 30 Riverside Spline & Gear Inc ...... 28 Schafer Gear Works...... 11 Schwartz Precision Gear Co...... 48 Setco...... 39 Stor-Loc...... 41,49 TalkGears.com...... 40 www.hanikcorp.com The Gear Works -- Seattle Inc...... 48 HANIK CORPORATION Tianjin Jingcheng Machine Tool...... 39 TSA America LLC...... 49,IBC

gearsolutionsonline.com • JANUARY 2008 • GEAR SOLUTIONS 51 Our Conversations scottLynch president and Secretary Q&A With Industry Leaders American Bearing Manufacturers Association

GS: When was the organization founded, ogy. These courses are led by Professor Ted and who was involved? Harris, a former SKF employee who is cur- SL: The first meeting of the American Bearing rently on the faculty at Penn State University. Manufacturers Association was held in 1917 We also joined forces with the AGMA to teach in New York City. At the time it was an infor- a course on bearing failure at the recent mal committee formed to aid the production GEAR EXPO in Detroit, and we’ve entered into of bearings during World War I. While most a partnership with the Society for Tribologists of the companies represented were based in and Lubrication Engineers to offer a course the United States—as is still the case with to their members. So we’re not only train- our membership—some international manu- ing people in the bearing industry, but also facturers were present. Many of those found- those in related fields about our industry. ing companies no longer exist independently, As I’ve mentioned, one of our major initia- with years of consolidation and acquisition tives for the coming year involves employee in the bearing industry. Of the top six or recruitment, and we’re in the final stages of seven global bearing manufacturers, all man- developing materials such as a brochure that ufacturer in the United States, but only The we’ll be able to offer online and as a printed Timken Company is a U.S.-headquartered piece to share with career placement offices corporation. and engineering departments at a number of universities that our members have long- GS: Does the ABMA have counterparts in time, ongoing relationships with. The idea is other countries? to make students who are considering what SL: Yes, we do. For instance, there are bear- fields they might like to enter aware that ing manufacturing industry associations in the bearing industry exists, what it entails, China, Korea, India, and Brazil, among other and what you should study in order for it to countries. In 2006, ABMA, along with our become a successful and vital career path. counterpart in Europe, the Federation of As is the case with any manufacturer, we European Bearing Manufacturers Association, need to overcome the image of “industry” as “We want to help ensure a and in Japan, which is the Japanese Bearing involving manual labor alone and make clear Industrial Association, created the World to them that technological advances have Bearing Association. This organization is literally transformed the workplace. Sure, focused on issues dealing with the global manufacturing still takes place, but it’s much strong U.S. manufacturing bearing industry, including counterfeiting and cleaner than in days past, and profession- the environment. als in areas such as application, computer, design, and mechanical engineering are at GS: Can you give us a snapshot of the a premium. This material is being developed sector for the bearing ABMA’s primary activities? by our HR committee, which is made up of SL: Well, since our inception we have been representatives from more than a dozen of the collective voice of the U.S. bearing indus- our member companies, so we’re beholden industry while encouraging try. Today our association is focused on a few to them for this important and useful con- key areas, including education of its mem- tribution. bers, standards development, and the collection of industry statistics. We’ve long been GS: Sounds like an active, vital, forward- global success for the involved in industry standards development. thinking organization. Our standards program is very active, and SL: That’s definitely our goal. The way I look we are the bearing standards developer for at the ABMA is that it’s a national associa- the United States and secretariat for a num- tion with an eye also trained on international industry.” ber of related ISO technical committees. I’d concerns and events. We want to help ensure say that two of our major thrusts at present a strong U.S. manufacturing sector for the involve education and employee recruitment bearing industry while encouraging global and retention. When it comes to education, success for the industry, and one way we’re since 1995 we’ve offered courses aimed achieving this is by working to understand at training bearing engineers. Our most the worldwide supply chain network in order popular courses involve essential concepts to enhance manufacturing overall. and advanced concepts in bearing technol-

FOR MORE INFORMATION:

Contact Lynch at (202) 367-1155 or [email protected]. Go online to [www.americanbearings.org].

52 GEAR SOLUTIONS • JANUARY 2008 • gearsolutionsonline.com

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