Special Involute Gears for Prototype Testing

GEAR SOLUTIONS MAGAZINE

Your Resource for Machines, Services, and Tooling for the Gear Industry RAPID AND PRECISE MANUFACTURING OF SPECIAL INVOLUTE GEARS FOR PROTOTYPE TESTING

ISSUE FOCUS Gear Design | Involute Gears RAPID AND PRECISE MANUFACTURING OF SPECIAL INVOLUTE GEARS FOR PROTOTYPE TESTING

COMPANY PROFILE SMT AUGUST 2020

AUGUST 2020 gearsolutions.com ISO 9001 AS9100 ISO 13485 ITAR Certified WBENC

CMY

World-class Gears for ... Helicopters Fighting Vehicles For Those Battle Tanks Armored Personnel Carriers Support Vehicles Unmanned (UAV/UCAV) Who Know Combat Aircraft Autonomous Vehicles Military Transport No Limits Amphibious Assault Ships Submersibles Advanced Materials, Engineered for Extreme Conditions

Excellence Without Exception ... 815.623.2168 ... forestcitygear.com

www.heat-treatment-services.com

ALD is a leader in vacuum process technology and heat Global service centers treatment services. ▪ LIMBACH OBERFROHNA Precision and perfection in the pieces that we treat under our patented thermal process. ▪ GERMANY

▪ PORT HURON, MICHIGAN Leaders in the control of distortion ▪ Low Pressure Carburizing ▪ USA ▪ High pressure gas quenching Gas Nitriding ▪ RAMOS ARIZPE, COAHUILA ▪ ▪ Ferritic Nitro Carburizing ▪ MEXICO ▪ Normalizing ▪ Hardening ▪ Annealing ▪ Brazing ▪ Cryogenic Treatments ▪ Engineering services and process development Thomas Lord, Sales Director Prototype and trials United States ALD Port Huron ▪ ALD Thermal Treatment Inc. 2656 24th Street Port Huron, MI, USA 48040 Cell Number +1 (810) 300-1437 Edwin Orozco, Sales Director – Mexico Email: [email protected] Office Phone +52 844 866 9791 Cell Phone +52 1 844 277 2257 Christopher Totten, Sales – Canada / USA, [email protected] Office Phone +1 810 357 0634 [email protected] Cell Phone +1 810 300 3601 e-mail: [email protected] Moises Garcia – Sales Director - Bajio Cell Phone +521 (844) 277 2254 Mexico ALD Tratamientos Térmicos S.A. de C.V. [email protected] FEATURES

RAPID AND PRECISE MANUFACTURING OF SPECIAL INVOLUTE GEARS FOR PROTOTYPE TESTING Even though the high production times per test gear compared to gear hobbing 30 can be compensated by the elimination of long design and procurement times for special production tools, a suitable method is available for the fast, precise, and cost-efficient production of special gears for prototype tests.

By CHRISTIAN WEBER, M.Sc., DR.-ING. THOMAS TOBIE, and PROF. DR.-ING. KARSTEN STAHL

OPTIMIZATION OF RACK AND PINION 38 FOR OFFSHORE JACK-UP APPLICATIONS Gear design has multiple parameters from which the gear designer can choose – while some are beneficial, some can negatively affect the system.

By Adrian Nowoisky

SERVING ALL SECTORS OF THE TRANSMISSION AND DRIVELINE DEVELOPMENT INDUSTRY 46 COMPANY PROFILE SMT is a globally integrated leader in mechanical transmission engineering services and software development.

By KENNETH CARTER

August 2020 3 Manufacturers of:

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

4 gearsolutions.com AUGUST 2020 • VOLUME 17, NUMBER 8 DEPARTMENTS 8 INDUSTRY NEWS Reports, data, and developments to keep you aware of what’s happening with your colleagues in the gear-manufacturing industry around the country and world.

AMB schedules first face-to-face event Honeywell, SLM Solutions develop after COVID 19 break. qualifications for aluminum builds.

In this section, the premier supporter of gear manufacturing in the United States and beyond shares news of the organization’s activities, upcoming American educational and training opportunities, technical meetings and seminars, Gear Manufacturers standards development, and the actions of AGMA councils and committees. 19 Association

24 MATERIALS 26 TOOTH 28 HOT MATTER TIPS SEAT E. BUDDY DAMM BRIAN DENGEL D. SCOTT MACKENZIE FUTURE OF GEAR DESIGN RELIES WHAT, PRECISELY, IS MY GEAR FRACTURE MECHANICS AND FATIGUE ON OVERCOMING PRESENT MADE OF? CRACK GROWTH Improved production efficiency through Almost 90 percent of the steel produced Fracture mechanics and fracture toughness optimized machinability or heat-treat is carbon steel, but alloy steel, stainless measurements can be used directly in response can result in lower costs – and steel, or tool steel are possibilities as design, becoming an enormously useful tool more contract wins. well. for determining the life of a component.

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

RESOURCES 54 MARKETPLACE

55 ADVERTISER INDEX DANIEL WEIS Sales Team Leader at Neugart USA COVER PHOTO: SHUTTERSTOCK

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

August 2020 5 FROM THE David C. Cooper FELLOWS 50-8/50-12 GEAR SHAPERS EDITOR PUBLISHER HYDROSTROKE SHAPERS • REMANUFACTURED IN 2017

EDITORIAL Industry keeps adapting Kenneth Carter to the new normal EDITOR Jennifer Jacobson he craziness that seems to be the driving force of 2020 has affected almost every part of ASSOCIATE EDITOR Tour lives — from the tiniest things we may take for granted to the larger health issues Joe Crowe that keep us up at night. CONTRIBUTING EDITOR As we try to make sense and adapt to what has become a new normal, Gear Solutions has tried to adapt as well. Our August issue and our September issue were originally scheduled to be a spring- e’ve g SALES h, w ot th board for the International Manufacturing Technology Show. But like so many other 2020 a a Dave Gomez e t! tradeshows, the organizers were forced to shift gears due to the coronavirus pandemic. Y NATIONAL SALES MANAGER I must applaud IMTS for working toward making the best lemonade out of the lemons Tom McNulty COVID-19 has thrown at us. Even though the Chicago show is officially canceled, IMTS REGIONAL SALES MANAGER organizers are working to take much of the tradeshow virtual. A virtual experience means no face-to-face camaraderie as with past shows, but attendees will still get the benefit of IMTS’ experts and presenters. And I suspect no one is going to really miss their annual CIRCULATION soft pretzel food run. (OK, full confession: I do love a soft pretzel.) Teresa Cooper It is somewhat of a relief to know that technology has been an awesome tool in keeping MANAGER a lot of our business going in these weird times. Jamie Willett With physical tradeshows on hold, please take time to see how Gear Solutions can also ASSISTANT be your ally in getting your message to your customers. We offer many ways in which to remind the industry that your products and services are available. That’s good news for your audience in search of the very services and products that DESIGN you can provide every day. And with the world trying to cope with economic and medical Rick Frennea hardships, the deep reach Gear Solutions can provide is more important than ever. CREATIVE DIRECTOR With that in mind, I hope you find the involute gearing and gear design articles in our August issue of interest. Michele Hall GRAPHIC DESIGNER In a fascinating article from Christian Weber, Thomas Tobie, and Karsten Stahl — all with the University of Munich’s Gear Research Centre — the authors share their insights on the rapid and precise manufacturing of special involute gears for prototype testing. CONTRIBUTING Next up, frequent contributor Stephen Radzevich discusses the most critical accom- WRITERS plishments in the scientific theory of gearing. REBECCA BRINKLEY And, as always, you’ll find some expert and innovative advice from our columnists. I E. BUDDY DAMM always appreciate the wisdom and time they volunteer for the magazine. BRIAN DENGEL With all that in mind, a final reminder that Gear Solutions is here to serve you. If you D. SCOTT MACKENZIE ADRIAN NOWOISKY have any suggestions or would like to contribute, please contact me. I’m always looking STEPHEN RADZEVICH for exciting articles to share. KARSTEN STAHL Stay safe and healthy out there, and, as always, thanks for reading! THOMAS TOBIE CHRISTIAN WEBER We have the world’s largest stock of used late-model Fellows Gear Shapers. Vertical Logo Horizontal Logo WE OWN WHAT WE SELL, AND WE KNOW WHAT WE’RE SELLING! KENNETH CARTER, editor [email protected] (800) 366-2185 x204 REMANUFACTURED

PUBLISHED BY MEDIA SOLUTIONS, INC. Coop wants to use this one for the website RETROFITTING CALL FOR ARTICLES Have a technical paper or other work with an 860-223-7778 educational angle? Let Gear Solutions publish it. Contact the editor, P. O. Box 1987 • Pelham, AL 35124 CUSTOM MACHINES www.NewEnglandGear.com Kenneth Carter, at [email protected] for how you can share (800) 366-2185 • (205) 380-1580 fax your expertise with our readers. David C. Cooper Teresa Cooper PRESIDENT OPERATIONS 343 JOHN DOWNEY DRIVE • NEW BRITAIN, CT 06051-2907 • PHONE 860-223-7778 • FAX 860-223-7776 • [email protected] 6 gearsolutions.com FELLOWS 50-8/50-12 GEAR SHAPERS HYDROSTROKE SHAPERS • REMANUFACTURED IN 2017 Yeah, we’ve got that!

We have the world’s largest stock of used late-model Fellows Gear Shapers.

WE OWN WHAT WE SELL, AND WE KNOW WHAT WE’RE SELLING!

REMANUFACTURED RETROFITTING 860-223-7778 CUSTOM MACHINES www.NewEnglandGear.com

343 JOHN DOWNEY DRIVE • NEW BRITAIN, CT 06051-2907 • PHONE 860-223-7778 • FAX 860-223-7776 • [email protected] Xxxxxxxx 20XX 7 INDUSTRY NEWS NEW TRENDS, SERVICES & DEVELOPMENTS

event. “The acquisition for the AMB Technology Forum has already started and the feedback so far is positive,” Mey said. The exhibitors want to use the forum to present a selection of their innovations which were originally intended for AMB. Markus Horn, managing director at Paul Horn, said, “We are taking part in the AMB Technology Forum because we are satisfied with Messe Stuttgart and AMB — both as a trade fair and forum.” The AMB Technology Forum will be the first opportunity since the start of the COVID-19 pandemic to take part in a high-ranking face-to-face event again. “In my opinion, it is important that the AMB Forum has a signal effect: Life goes on. And this is exactly what we need,” Horn said.

MORE INFO www.amb-messe.de/forum Honeywell, SLM Solutions

The AMB Technology Forum is the first face-to-face industry event this year with presentations and an develop qualifications accompanying table-top exhibition. (Courtesy: Messe Stuttgart) for aluminum builds tion and ideas with the experts on the Honeywell and SLM Solutions achieved an AMB schedules first respective topic every day in the Stuttgart important success in their development face-to-face event International Congress Center. The aim is collaboration for the qualification of alu- to present new technologies and innova- minum parts printed with high-layer thick- after COVID-19 break tions in the presentations, as well as estab- nesses. Newly developed parameter sets for Due to the novel coronavirus pandemic, the lish new contacts in the matchmaking area aluminum alloy F357, a new beryllium-free industry event, AMB in Stuttgart, cannot where visitors and exhibitors can meet. In version of AlSi7Mg0,6 (A357), lead to con- take place this year in its usual format. the table top exhibition, the manufactur- siderably improved material properties “With the AMB Technology Forum in ers can look forward to personal meetings compared to parts produced through die- September, there is still a good reason to and questions from visitors. Exhibitors also casting. The work between Honeywell and come to the Stuttgart trade fair grounds,” have the option of recording the presenta- SLM Solutions, announced in 2019, aims to said Gunnar Mey, department director for tions on video and making these available reduce manufacturing times and costs to Industrial Solutions at Messe Stuttgart. In on various online channels for everyone produce 3D-printed aircraft components the AMB week from September 14, various who cannot be in Stuttgart. A maximum that meet the high requirements of the topics will be the focus of presentations of 500 visitors each day is planned due to aerospace industry. and the accompanying table-top exhibi- COVID-19 restrictions. As part of the collaboration that kicked tions. Planned events include software and Mey confirms that the AMB Technology off in 2019, Honeywell began qualifica- control, tool solutions, machine elements Forum — in compliance with all current tion efforts for aluminum builds using and peripheral devices, machine tools, and hygiene and distancing regulations — should an increased layer thickness of 60 and 90 machine tool automation. make possible the personal exchange of µm on their quad-laser SLM®500 Selective Interested parties can expect compact ideas and opinions and the haptic experi- Laser Melting Machine. SLM Solutions pro- knowledge and an exchange of informa- ence within the framework of a face-to-face vided generic aluminum parameter sets for

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

8 gearsolutions.com Alloyed wins prestigious Institute of Physics business award Alloyed, the company formed from the merger of OxMet Technologies and Betatype late last year, has won the prestigious Institute of Physics Business Start-up Award 2020. The award, submitted by OxMet prior to the merger, recognizes the scientific work of the team that resulted in the innovative system brand: Alloys By Design (ABD™). The ABD digital platform is setting new As part of a collaboration that kicked off in 2019, standards for metal material development Honeywell began qualification efforts for aluminum builds using an increased layer thickness of 60 and for advanced manufacturing applications 90 µm on their quad-laser SLM®500 Selective Laser in a broad range of industry sectors. The Melting Machine. (Courtesy: SLM Solutions) commercialization of the ABD-850AM and ABD-900AM alloys, specifically for additive Honeywell to complete material qualifica- manufacturing, highlights the real poten- tion to achieve optimal material properties. tial of the platform and points to its capa- The development of these new parameter bilities for developing custom materials that sets for aluminum alloy F357 using a layer meet specific requirements from industry. thickness of 60 µm and 700 W lasers has now The Institute of Physics (IOP) is the profes- reached an important milestone. Material sional body and learned society for physics, properties have significantly increased in and the leading body for practicing physi- comparison to conventional die-cast parts cists, in the UK and Ireland. With a rich his- and are now exceeding overall acknowl- tory of supporting business innovation and edged metallic properties for aerospace. growth, it is committed to working with Aluminum alloy F357 is not only light- “physics-based” businesses and companies weight but offers a significantly better cor- that apply and employ physics and physicists. rosion resistance and desired mechanical The IOP’s prestigious Business Awards are properties, such as high-strength across a unique in the U.K. and Ireland in recogniz- wide temperature range in comparison to ing the significant contribution that physi- conventional aluminum alloys. It has a great cists and physics make in industry. weldability and excellent suitability for post- There are three categories of awards — processing, like mechanical machining or Business Innovation, Business Start-Up, and electrochemical such as anodizing. This the Lee Lucas Award (for early-stage compa- combination of properties enables F357 to be nies in the medical and healthcare sector) perfectly suited for thin-walled and complex — so businesses at any stage of development structures in, for example, the aerospace or are eligible, from start-ups to multi-national automotive industry. corporations. About his work with the SLM®500, Dr. The IOP Business Start-Up Award specifi- Sören Wiener, senior director technol- cally recognizes and celebrates young com- ogy and advanced operations at Honeywell panies with a great business idea founded Aerospace, said, “In particular, the open on a physics invention, with the potential architecture system of the SLM® machine for business growth and significant societal provides huge advantages such as high flex- impact. ibility and parameter sets can be customized. Commenting on the IOP Award, Michael With this open access strategy and the great Holmes, CEO of Alloyed, said, “Everything support of SLM Solutions, we step forward to we do in every bit of our business rests on the achieving our next goals.” foundations provided by physics, and we’re Benjamin Haas, product manager for delighted that the judges believe we have materials & parameters at SLM Solutions made a contribution to the field.” said, “It is a privilege to work together with Institute of Physics President, Jonathan one of the leading companies in the aero- Flint, said, “The IOP Business Awards recog- space world. This way, we can learn a lot nize and reward the achievements of physics- from each other leading to perfectly suited, based businesses of all sizes; innovative com- industry proven solutions from which all of panies that have developed new technologies our customers can benefit.” or repurposed existing ones, and that are at the cutting edge of the U.K. and Ireland’s sci- MORE INFO www.slm-solutions.us entific research and development. August 2020 9 INDUSTRY NEWS

(speed, temperature, vibrations, etc.) are available. For each application, respective features are tailored to the specific use of each unit, such as hydraulic couplings, or Taconite seals that effectively protect shaft sealing rings against abrasive dust and corrosion. This customization ensures that each unit will perform at the highest level throughout its entire lifecycle.

MORE INFO www.nord.com

Alloyed’s prestigious Institute of Physics business award is unique in the U.K. and Ireland in recognizing the significant contribution that physicists and physics make in industry. (Courtesy: Alloyed) AEM hails USMCA

“These companies, old and new, large and ratios from 5.54:1 to 400:1, as well as up to benefits to equipment small, have the power to drive the economy. 30,000:1 with an auxiliary primary stage They use the applications of physics to cre- gear unit. Mounting and fastening can take manufacturers ate positive individual, social, industrial place on all six sides of the gear unit. Association of Equipment Manufacturers and economic change, both at home and Nord has developed its MAXXDRIVE® XT (AEM) President Dennis Slater issued the overseas. Series two-stage, right-angle gear units for following statement as the United States- “Rarely has the need to recognize and applications where high-speed (low ratios) Mexico-Canada Agreement (USMCA) entered encourage our scientists been more appar- and high-power performance are required. into force: ent. We must continue to encourage, reward As a standard, the series is equipped with a “The USMCA entering into force today and invest in our researchers. Their commit- ribbed UNICASE housing and integrated axial is great news for equipment manufactur- ment, drive and imaginations help to keep fan. Due to the increased surface area and air ers and our industry’s 2.8 million men and us comfortable, healthy and safe.” guide covers, cooling air flow is increased to women working across the United States achieve a very high thermal limit. In many and Canada. This marks the start of a new MORE INFO www.alloyed.com cases, additional cooling is not required for chapter for North American trade. USMCA these units. Large roller bearings and center expands agricultural market access, estab- distance also increase the load capacity and lishes rules for e-commerce, strengthens Nord MAXXDRIVE® service life of the components. labor and environmental protections, and Because Nord’s solutions are based on a updates customs rules that will cut red tape industrial gear units for modular system, they can offer complete, and make it easier for U.S. manufacturers customized drive systems for a wide variety to sell to their Canadian and Mexican cus- heavy-duty applications of heavy-duty applications. This modularity tomers. We applaud President Trump, Vice MAXXDRIVE® industrial gear units from also provides attractive solutions for price- President Pence, Senate Majority Leader Nord Drivesystems are characterized by sensitive industries with a comprehensive McConnell, and House Speaker Pelosi to get high power density, quiet operation, and top range of variable frequency drives (VFDs), this agreement to the finish line.” reliability — ideal characteristics for use in motors, and gear units, as well as attached AEM was an ardent supporter of the heavy-duty applications. components such as couplings, brakes, base USMCA since it was first proposed. The MAXXDRIVE® industrial gear units swing frames, and many other options. For association actively advocated for the indus- from Nord Drivesystems provide high out- example, various versions of drive and driv- try’s priorities with U.S. and Canadian gov- put torques from 132,000-2,250,000 lb-in. en shafts, mountings, sealing systems, back ernment stakeholders, participated in the and are ideal for use in heavy-duty applica- stops, auxiliary gear units, cooling equip- USMCA Coalition, co-hosted the Honorable tions such as bucket elevators, agitators, belt ment, and sensors for condition monitoring Mike Pence, Vice President of the United drives, mixers, mills, drums, and crushers. States, at an equipment manufacturing Thanks to their rigid one-piece UNICASE™ facility in August 2019 to raise public sup- housing, they achieve a longer bearing port for the agreement, supported the work life than gear casings manufactured from by Chairman Richard Neal (D-Mass.) and jointed parts. They also ensure efficient the nine members of the House Democrats’ power transmission and high tolerance for Trade Working Group, and ran an ongoing peak loads and impacts. Additionally, their public education campaign on the various large low-friction rolling bearings allow benefits of a ratified USMCA. for extremely high axial and radial load The International Trade Commission capacities and high-precision axis align- reported last year that the implementation ment ensures quiet operation and a long, low of the USMCA could add up to$68 billion to Nord’s two-stage MAXXDRIVE® XT right-angle gear maintenance service life. Nord industrial units are specially designed for applications that the U.S. economy and create 176,000 jobs. gear units are offered as parallel gear units require low-speed ratios combined with high-power or as right-angle gear units and cover speed performance. (Courtesy: Nord USA) MORE INFO www.aem.org 10 gearsolutions.com a recent edition to Solar Atmospheres of Solar Atmospheres of Western PA, said, “We have a great team that Western PA celebrates can pull together, under any circumstances, to get work done. Solar maintains the high- AS9100 anniversary est standards by keeping safety, quality, and efficiency in check and our customers in the Solar Atmospheres of Western PA celebrated foreground. Solar exercises a proven value thirteen years of AS9100 certification. Like system, integral to society, and empowers the complexities of ever-changing customer people, shaping a bright future.” needs, 2020 proves to be challenging businesses. Impacts to daily routines, course of www.solaratm.com The Type SDA-V caged ball screw is ideal for a MORE INFO wide range of applications, from small electronic business, personal liberties, and even audit component machinery to large general industrial. scopes bear a brunt of ushering in a new era. (Courtesy: THK) This new era is intricately woven with THK adds high-speed, COVID-19, populous instability, and inter- high-speed operation. Type SDA-V/SDAN-V twined with increasingly stringent stan- compact caged nut dimensions conform to DIN standards dards, revised industry specifications, and (DIN69051-5). customer requirements. ball screw The Type SDA-V caged ball screw is ideal Even with these new complexities, Solar THK’s new Type SDA-V/SDAN-V caged ball for a wide range of applications, from small passed this milestone for more than a decade screw is engineered to enable the devel- electronic component machinery to large of accreditation without any major findings. opment of high-speed, compact machine general industrial. Fifty-nine products are The live audit, which was conducted for the designs. available with a combination of shaft diam- very first time, used a combination of email, Featuring newly developed circulation eters from 12 to 50 and leads from 4 mm to telephone, and video conferencing to grade components, the Type SDA-V/SDAN-V picks 50 mm. Clearance can be selected, including Solar’s QMS on recent aerospace work. The up balls in the tangential direction and an axial clearance of 0 or less. comprehensive review addressed recent achieves a maximum rotational speed of The Type SDAN-V caged ball screw is events as risk and Solar’s response as effective. 5,000 RPM (DN value of 160,000 max.). Torque designed with higher axial rigidity than Melissa Gruszka, quality manager and remains stable even during long periods of the Type SDA-V. It is suitable for use with

WWW.AMGEAR.COM

AEROSPACE/DEFENSE

CONTROLS

MEDICAL DEVICES Precision Gear Products RUSSELL, CUSTOM PRECISION GEARS STOCK : HOBS : HSS & CARBIDE ISO2015, AS9100, DDTC HOLBROOK & STOCK : SHAPERS : Disc & Shank STOCK : MASTER GEARS HENDERSON, INC. RFQ on specials gear tools welcome [email protected] 25 E Spring Valley Ave., Maywood, New Jersey 07607 Diametral Pitch 12 and finer FOSTER CITY, CA P: 201-226-9000 F: 201-226-9004 E: [email protected] 800-554-3150 CELEBRATING 100 YEARS IN BUSINESS STOCK AVAILABLE www.tru-volute.com

August 2020 11 INDUSTRY NEWS

NC machine tools and precision equipment been designed and manufactured to meet high production, and prototyping. when is it necessary to minimize displace- the strictest requirements. THK’s experi- “We’re excited to be representing Takumi ment from the force of cutting. Shaft diam- enced global engineering team can provide USA,” said Andy Roeder, sales. “We have been eters range from 31 to 50 and leads from customized linear motion solutions from very impressed with the high-speed machin- 10 mm to 20 mm. A double nut is used to their standard linear motion products as ing and outstanding surface finish of the achieve axial clearance of zero or less. Full- well as from mechatronics products for the Takumi U-Series 5-Axis machining centers. ball versions are available for both the Type most demanding applications. Takumi has truly created durable CNC SDA-V and the Type SDAN-V. machines that result in higher productiv- The Type SDA-V/SDAN-V features patent- MORE INFO www.thk.com ity through speed, accuracy, and reliability. ed THK Caged Technology for smooth and With industry-standard CNC controls (Fanuc quiet motion. Caged Technology employs a or Heindenhain), we will be able to help cus- synthetic resin cage with a patented curva- Takumi taps Superior tomers find the right machining center to ture that cradles each ball and separates it meet their needs.” from the next. The spaces between the roll- Equipment Solutions Superior Equipment Solutions will be ing elements retain grease and act as a lubri- offering sales, service, parts, training, and cation system for long-term maintenance- for two states applications support for Takumi USA cus- free operation. Other Caged Technology ben- Takumi USA has named Superior Equipment tomers in Kentucky and Southern Ohio. efits include increased speed and accuracy, Solutions (SES) of Franklin, Ohio, as its exclu- “Superior Equipment Solutions is a great decreased noise levels, low dust generation sive full-service distributor for Kentucky and addition to the Takumi USA dealer net- and long life. Southern Ohio. SES supplies manufacturers work,” said Cory Miller, Takumi USA General The Type SDA-V/SDAN-V complies with with CNC machine tools, advanced metal Manager. “We know they’re going to help us conventional JIS (Japanese Industrial cutting equipment, and process engineer- sell machines, but even more important, we Standards) as well as ISO (international stan- ing. The company offers turning centers, know they have the knowledge and experi- dards) and DIN (German industry standards). horizontal and vertical machining centers, ence to provide customers with the tools and THK manufactures a wide range of lin- boring mills, bridge mills, grinders, EDM, machinery options they need to succeed.” ear motion products, including LM guides, and metrology/inspection. SES prides itself ball screws, mechanical actuators and ball in serving all industries including aerospace, MORE INFO www.takumiusa.com splines, and more. All THK products have medical, automotive, mold/die, job shops, www.supequipment.com

No Money for Capital Equipment Purchases? NO PROBLEM! REPOWER

SIGMA 3 M&M 3025 REPOWERED BY Penta Gear • Analytical Inspection Machine • Roll Testers • Single Flank • DOB Inspection Gauges

6161 Webster St. Dayton, OH • Tel: 937-660-8182 • Fax: 937-660-4521 • [email protected] • gearinspection.com

12 gearsolutions.com SKF recognized as matrix and the hardenability of the steel. The Alloy Composition Variation Modeling: Dante decomposition rate is a function of time, tem- 5.0 introduces the ability to model slight vari- a Supplier of the Year perature, and carbide size factor. ations in steel alloy composition and its effect Residual Stress Relaxation Model: This on the material’s hardenability. The model is by manufacturing group model describes the relaxation of residual intended to capture the variation witnessed SKF was recognized as a Supplier of the Year stresses during heating and holds at high in production. The model affects the transfor- for 2019 by American Axle & Manufacturing temperature. The model is intended to pre- mations to ferrite, pearlite, and bainite. (AAM) at AAM’s 26th Annual Supplier Day, dict stress relaxation during a stress relief Liquidus/Solidus Latent Heat Model: This held virtually from Detroit. processing step, annealing step, normalizing model describes the latent heat released as SKF was recognized for continued and step, or during the austenitizing process. The a steel transforms from the liquid state to consistent exceptional performance saying, relaxation rate is a function of time, tempera- the solid state and the latent heat absorbed “The SKF team proactively approaches AAM ture, and stress. as a steel transforms from the solid state to with new opportunities that create win/win outcomes and engages openly and competi- tively on new technology.” This is the second Supplier of the Year Rings DISCs award SKF has received from AAM. 4 -144 OD “SKF and AAM have worked together to ” ” UP to 60” bring high-quality, innovative and competitive bearings and sealing solutions into the automotive marketplace. We deeply value our relationship with AAM and it is a great honor to be recognized as a Supplier of the Year,” said Jim Seta, president, Automotive OEM Bearings, SKF Americas. MORE INFO www.skfusa.com EASY Dante Solutions releases heat-treatment simulation software Dante Solutions, Inc. has released Dante Does It 5.0, the most advanced heat-treatment simulation software from Dante Solutions. Included in Dante 5.0 are several new features designed to describe the physics of steel heat treatment more accurately; they include: Carbon Separation Model: This model McInnes Rolled Rings believes in providing describes the rejection of carbon as the steel superior service and outstanding quality transforms to ferrite from austenite. The additional carbon then enters the surround- products, ensuring the entire sales process is as ing austenite matrix, increasing the local easy and as fast as possible for our customers. hardenability of the steel. Carbide Decomposition Model: This model When it’s seamless, it’s McInnes. describes the decomposition of primary carbides during heating processes. The amount of total carbon (carbon in the matrix and carbon in primary carbides), carbon in primary carbide form, and a carbide size factor are defined as initial conditions to the model. The carbon and carbide values can be uniform throughout the material or as a profile, as from a carburizing process. The carbon in carbide form will enter the matrix 1.877.695.0301 www.McInnesRolledRings.com/Easy during heating and soaking at high temperature, increasing the carbon in the austenite

August 2020 13 INDUSTRY NEWS the liquid state. The model is intended to be ware, improving stability. Several mathemat- Erler has held a number of leadership used when modeling any phenomena involv- ical algorithms were also modified, improv- positions with ASME including as a mem- ing a melt pool, such as welding or additive ing convergence and robustness. Dante 5.0 is ber of the Society’s Board of Governors, as manufacturing. now available for installation. a member of several ASME codes and stan- Abaqus Plug-In: Dante Solutions has dards committees, developed an Abaqus Plug-In designed to aid MORE INFO www.dante-solutions.com including as vice in Dante model setup. The Plug-In includes president of ASME’s means to define material, initial condi- Nuclear Codes & tions, boundary conditions, and much more. Bryan Erler begins Standards and past Abaqus users no longer need to manually chair of the Board modify input files. The entire Dante model term as ASME’s of Nuclear Codes can now be easily constructed within Abaqus and Standards. He CAE using the Dante Plug-In. 139th president also served as the Dante Utility GUI’s: Dante Solutions has Bryan Erler, P.E., began his term as the Society’s secretary/ Bryan Erler developed Graphical User Interfaces (GUI’s) 139th president of the American Society of treasurer. for all of its utilities offered to aid in mate- Mechanical Engineers (ASME), the Society “It’s the honor of rial, model, and process development. Please announced during its virtual annual my career to be able contact a Dante Solutions engineer for more meeting. An active member of ASME serve you as ASME information on the type of utilities offered. since 1991, Erler has been an executive president in what MatSim Utility: Dante Solutions latest util- and expert in the nuclear power industry will surely be an ity combines the power of the Dante phase for more than 45 years with significant exciting and extraor- transformation models into an easy to use leadership roles and responsibilities in dinary year. I am con- utility. Predict volume fraction of phases the designing of electric power plants fident that together, from defined heating and cooling rates, plot as an owner and senior vice president of we will turn a time Mahantesh Hiremath temperature-strain curves, and much more. Sargent & Lundy. of unprecedented Please contact a Dante Solutions engineer for He is the recently retired president of challenge into one of unmatched opportu- more information. Erler Engineering, Ltd., where he served as nity,” Erler said. Several bugs were removed from the soft- a consultant to the power industry. Outgoing president Richard Laudenat,

COMPACT. CONSISTENT. COMPETITIVE. NEW Release kapp-niles.com 2020

KISSsoft Highlights ▪ Rainflow method for load data analysis ▪ Reliability evaluation with AGMA 6006, VDMA 23904 and Bertsche ▪ Revised tooth root and flank rating according to ISO 6336:2019 ▪ Scripting language for automation and

KISSsoft AG/Gleason Sales extension of calculations Brian P. Stringer ▪ Gearbox data exchange with REXS Phone (585) 494-2470 [email protected] Free trial version at www.KISSsoft.com

14 gearsolutions.com

GearSol_KISSsoft_Release2020_92_25x123_83mm.indd 1 28.04.2020 12:59:15 P.E., thanked the Board of Governors and has held leadership positions at ASME for the ASME Executive Director/CEO Tom Costabile past 25 years. Mazak opens new for their support throughout the past year, Paul Stevenson is executive vice presi- expanded spindle while acknowledging the unique challenges dent of McCormick Stevenson Corporation brought on by the COVID-19 pandemic. “As in Clearwater, Florida, an engineering rebuild department always, our collaboration, passion, and devo- services provider serving government and As part of its most recent $15 million invest- tion to ASME are what make this organiza- industry clients developing systems for the ment in its Florence, Kentucky-based man- tion so robust, and in these times, so resil- U.S. Department of Defense. ufacturing campus, Mazak Corporation ient,” Laudenat said. He has been an active member of ASME has completed its newly expanded Spindle During the same event, Mahantesh since 2001. Rebuild Department, now in the company’s Hiremath, Ph.D., P.E. was introduced as South Building. The expansion coincides ASME’s president-nominee for the 2021-2022 MORE INFO www.asme.org with other Mazak investments, includ- term. Hiremath, an ASME Fellow, has been an active member of ASME since 1997. He served as a member of the ASME Board of Governors from AMORPHOLOGY 2015 to 2019. With a distinguished career spanning more than 30 years, Andrew Bicos he is one of only a DISRUPTING TRADITIONAL GEAR few engineers in the world to have PRODUCTION WITH designed and engineered systems in NOVEL ALLOYS AND PROCESSES four different envi- ronments — deep underground, offshore, on-ground and in space. ADVANCED GEAR PRODUCTION Richard Marboe In addition to Erler and Hiremath, three new members of the ASME Board of Governors also began their terms on July 1, 2020, and serve through June Flipping the paradigm on expensive gear production by 30, 2023. Andrew Bicos, nearly eliminating machining costs. Paul Stevenson Ph.D., a member of ASME for more than 25 years, is an independent consultant, POWDERS & COATINGS recently retired from The Boeing Company after more than 31 years. At Boeing, he worked in executive management in the R&D organization where he served as director of systems engineering and previously as chief engineer of the aeromechanics research group and director of flight sciences technology strategy. Proprietary coating methods create a smooth cosmetic surface, Richard Marboe, Ph.D., a member of ASME since 1982, is the recently retired direc- additional hardness, and corrosion resistance. tor of engineering services at the Applied Research Laboratory of The Pennsylvania State University. He has been responsible for facilities, design and fabrication, public Request more information: [email protected] release, export compliance, and safety. He

August 2020 15 INDUSTRY NEWS

enced factory-trained technicians use only genuine Mazak replacement parts to rebuild Mazak spindles. Within a tight turnaround window, these technicians perform every stage of the repair and rebuild process, provide comprehensive and trackable spindle documentation, and conduct stringent testing of every spindle. The expansion has not only made room for additional technicians but also allows the department to boost its rebuild output to 100 spindles per month.

MORE INFO mazakusa.com THK introduces more precise, stable SPR/SPS caged ball LM guide The new Type SPR/SPS caged ball LM Guide incorporates unique THK technology to achieve ultra-low waving and ultra-high rigidity. Featuring additional raceway grooves, ultra-long blocks, and an increased number of small-diameter balls, the Type SPR/SPS improves the precision of load- bearing strokes and provides stable motion. Mazak has significantly expanded the new spindle department’s work area, and the clean, bright, and By doubling the number of raceway ergonomic workspace will streamline rebuild operational flow, efficiency, and speed. (Courtesy: Mazak) grooves to eight, the Type SPR/SPS reduces the load on the balls by 50 percent and ing new technical centers in Northern LIVE, an ongoing series of online events enables ultra-low waving on a nanoscopic California, Florida, and — most recently — where attendees gain exclusive access to scale. In addition, the use of ultra-long Canada, all of which have been developed new never- before-seen Mazak manufactur- blocks allows for the incorporation of to provide local manufacturers with fast and ing technology. more balls and further reduces each ball’s reliable applications expertise, training, ser- Continual investments, such as the individual load. An increased number of vice, and support. Spindle Rebuild Department expansion, small-diameter load-bearing balls stabi- Mazak expansion efforts that also extend in its facilities allow Mazak to quickly and lizes support and decreases compression to its manufacturing plant, encompass the effectively fulfill customers’ evolving needs when under a load. The resulting ultra-low installation of a new state-of-the-art manu- for advanced machine tool technology and waving performance of the Type SPR/SPS is facturing cell with fully automated storage applications support for U.S. manufactur- comparable to that of static pressure guides, and retrieval system, six of Mazak’s most ing in industries that include medical, aero- while its ultra-high rigidity exceeds that of advanced machine tools and several of its space, automotive, construction and agricul- roller guides. Mazak Smooth Technology digital process ture equipment, automotive, and medical The Radial Type SPR and the 4-Way Equal monitoring solutions. The upgrades to the industries. The expanded and newly updated production facility, which has been expand- department will further improve the com- ed nearly 20 times since it opened in 1974, pany’s ability to quickly deliver spindles and will allow the company to satisfy growing reduce customer downtime. customer demand and provide the shortest The Spindle Rebuild Department sup- possible turnaround times. ports every Mazak machine tool spindle in In addition to visiting in person, indi- North America, including more than 2,000 viduals will soon be able to experience the different models covering a wide range new expanded Spindle Rebuild Department of horsepower ratings and speeds. As a and Mazak’s entire manufacturing cam- cost-effective option for its customers, the pus as part of an interactive 360 Kentucky expanded department will keep upwards of Campus Tour. This virtual interactive tour 1,000 rebuilt spindles in stock and ready for is part of Mazak’s recently launched three- exchange, especially those found in Mazak’s pronged holistic digital customer experi- most popular machine models. The Type SPR/SPS improves the precision of ence, which also features an immersive To guarantee that all original spindle load-bearing strokes and provides stable motion. Virtual Technology Center and All Axes™ specifications are met or exceeded, experi- (Courtesy: THK)

16 gearsolutions.com Load Type SPS are both capable of bearing hygiene regulations for holding trade fairs parts2clean in the team of Deutsche Messe loads in the radial, reverse-radial, and hor- in Baden-Württemberg, and limitations on AG. “Under the given circumstances, it izontal directions. The Type SPR is effec- international travel have led to a situation would not have been possible to success- tive on radial loads when force is applied where SurfaceTechnology GERMANY and fully stage the two trade fairs in Stuttgart perpendicular to the shaft. It is suitable parts2clean will not be held this year. The in October. Companies need reliable plan- for the stroke of heavy machines. The Type decision was made by the organizer in close ning, which called for a prompt decision. SPS positions each ball at a contact angle of coordination with the trade fair advisory We will now invest all of our energy in 45 degrees and bears loads from all direc- boards. restarting parts2clean in October 2021 and tions. It can be used in various positions, “We fought hard for both trade fairs, but SurfaceTechnology GERMANY in June 2022. such as horizontally and upside down. Rail in the end there’s no alternative to can- Once the current situation has been overcome, lengths for both types range from 160mm cellation,” said Olaf Daebler, global direc- both events will be needed more than ever.” to 3,090mm. tor SurfaceTechnology GERMANY and In numerous conversations with com- Applications include semiconductor manufacturing equipment, ultra-precision industrial machines, high-precision machining centers, lathes, surface grinders, FPD manufacturing equipment, inspection equipment, and high-performance measure- ment devices. The The Type SPR/SPS features patented THK Caged Technology for smooth and quiet motion. Caged Technology employs a syn- Power thetic resin cage with a patented curvature 2 that cradles each ball and separates it from of One the next. The spaces between the rolling elements retain grease and act as a lubrication system for long-term maintenance-free Your Objective: operation. Other Caged Technology ben- One face in perfect alignment with another. For infinity. efits include increased speed and accuracy, decreased noise levels, low dust generation and long life. THK manufactures the widest range of linear motion products, including LM guides, ball screws, mechanical actuators and ball splines and more. All THK products have been designed and manufactured to meet the strictest requirements. THK’s experienced Global Engineering Team can No problems. No distress. No delays. provide customized linear motion solutions That’s the same objective you have for choosing your gear producer. from their standard linear motion products Circle Gear’s objective is to engage with every customer’s objectives. as well as from mechatronics products for One to 1000 gears the most demanding applications. Customer designed or reverse engineered MORE INFO www.thk.com Gearbox repair, rebuild or redesign OEM or end-users SurfaceTechnology ISO 9001:2015 Certified GERMANY, parts2clean 1501 S. 55th Court, Cicero, IL 60804 canceled for 2020 (800) 637-9335 (708) 652-1000 / Fax: (708) 652-1100 After intensive discussions and consid- [email protected] erations, it was decided the trade fairs www.circlegear.com SurfaceTechnology GERMANY and

parts2clean, which were scheduled for Spiral and Straight Bevel Gears (Cut, Ground or Lapped) • Spur Gears • Helical Gears • October in Stuttgart, cannot take place Long Shafts • Herringbone Gears • Involute and Straight Sided Splines • Internal Gears • this year. Both events will return to regu- Worm and Worm Gears • Racks • Sprockets • ISO Certified

lar rotation. Partnering with QualityReducer to provide The uncertainty caused by the coronavi- Gearbox repair, rebuilding and reverse-engineering. rus pandemic, extensive restrictions, and

August 2020 17 INDUSTRY NEWS panies and associations, an increasingly holding trade fairs would have significantly be October 5-7, 2021. distinct picture has emerged: Due to the affected the usual appearance of the events. economic crisis in which some companies For trade fairs in Baden-Württemberg, for MORE INFO www.surface-technology- are struggling to survive, there are currently example, plans permit one person per 10 germany.de other topics on the agenda than attending a square meters in each exhibition hall. trade fair. However, the question of health SurfaceTechnology GERMANY will now and protection against infection is still very meet again at SurfaceTechnology GERMANY Milltronics announces important. Whether for business or private from June 21-23, 2022, in Stuttgart. Next year, reasons much of the population is minimiz- the SurfaceTechnology AREA will also be distribution agreement ing travel and contact. Especially interna- part of Hannover Messe in April 2021. tional travel is more difficult. Furthermore, The leading international trade fair for with EMEC Machine Tools hygiene concepts and political guidelines for parts and surface cleaning, parts2clean, will Milltronics USA, Inc., and EMEC Machine Tools, Inc., have executed a partnership agreement for distribution, service, and support of Milltronics Machine Tools. EMEC will distribute Milltronics products on an exclusive basis across the provinces of Manitoba, Ontario, and Quebec. Milltronics USA, Inc., is based in Waconia, Minnesota, and is a leading supplier of easy- to-use and cost-effective machine tools serv- GEARING AHEAD TO MEET ing job shops, tool rooms, tool & die, and other metal cutting customers. With more than INDUSTRY’S DEMAND 14,000 machines installed, the company has built its reputation on well-built machines FOR PRECISION equipped with a straightforward control and backed by superior service and support. EMEC will be offering sales, service, – SERVING – parts, training, and applications support for Aircraft • Aerospace • Actuation Milltronics customers within EMEC’s territo- ries. EMEC has a combined team of 20 service Instrumentation • Optic and applications technician between the Robotics • Radar • Medical Mississauga and the Montreal offices. Both Marine • Defense • Experimental offices have a showroom to allow custom- Prototype • Production ers to see machines in action, prepare time- studies, host educational seminars, and meet Hi-Performance Automotive with company representatives. “We at EMEC are excited by this new addition to our product line and are confident CNC Thread Grinding our new partnership with Milltronics will be a success. With their excellent line of prod- Nadcap Accredited: Heat Treatment, Induction Hardening, Passivation ucts and our shared commitment to superior support and service, we have all the ingredi- Precision Gear Products (up to AGMA Q14): ents to ensure a bright future for both of our companies. We look forward to working with Spur Gears, Helical Gears, Worm Gears, Anti-Backlash Gears, Cluster Gears, the Milltronics team to provide our custom- Clutch Gears, Face Gears, Planetary Gears, Gear Assemblies, Gear Boxes, ers with some new exciting solutions,” said Bevel Gears, Miter Gears, Metric Gears, Internal Gears, Idler Gears, Gear Rack Bill Mara, president of EMEC. & Pinion, Worms, Wormshafts, Splines, Spline Shafts, Serrated Shafts. “Canada has always been an important market for Milltronics. And while we always want to partner with a distributor that can help us sell machines, we really focus on STD Precision Gear & Instrument, Inc. those that do a great job taking care of the 318 Manley St. • W. Bridgewater, MA 02379 customer. EMEC has the capability and the track record of doing just that – before, dur- (888) STD-GEAR or (508) 580-0035 ing, and after the sale,” said Louie Pavlakos, general manager of Milltronics USA. Fax: (888) FAX-4STD or (508) 580-0071 E-mail: [email protected] • Web site: www.stdgear.com MORE INFO www.emecmt.com www.milltronics.com

18 gearsolutions.com JennyRebecca Blackford Brinkley ViceAGMA President Director of American Communicationsof Marketing & Gear Manufacturers AGMACommunications Association

Developing a new sales pipeline: Tips to help improve your strategy during a pandemic

elling has been around since the beginning of time. From day online, and your company needs to be in the mix. Going online cavemen bartering their hunted food to pioneers trading allows great ways to share photos and videos of your products with farmed goods, sales is one of the oldest professions known potential customers. Make sure to tag your trade association so they to man. Today, we see the modern-day salesman — you can share what you are doing. Smeet virtually on LinkedIn or on a Zoom call — who might have a Attend online socials: AGMA has been hosting monthly virtual different approach than the sales people hundreds of years ago, but socials that connect our members to talk about what is affecting them. it still remains one of the most critical positions at your company — More often than not, this type of forum is a great way to benchmark especially during this pandemic. They keep the cash flow coming in with others, get some useful insights, and share the challenges you and new business in the pipeline — which is a lot of pressure to put are facing with industry peers. Don’t be afraid to sign up and listen; on one department of a company. Do you find that your sales people you need to know you are not alone. are stressed out right now? We don’t doubt it. Advertise and sponsor: With all of the face-to-face events moving We all are very familiar now with the fact that COVID-19 has put to online platforms, it is important to get your logo and brand out serious strain on how manufacturers and other industries are selling there while you have the opportunity. Many associations and compa- their products. This holds especially true for the machine tool indus- nies are hosting webinars that are sharing really important informa- try that was relying on many of the 2020 tradeshows, where compa- tion that hundreds in your customer base are attending. Becoming nies would have exhibited their latest a sponsor or taking out an ad in the and greatest. IMTS, South By Southwest, industry publication is a very simple and and Inspired Home Show 2020 are affordable way to get your brand in front among hundreds of others that have of thousands of potential customers. It cancelled their face-to-face events due lets people know you are still working, to pandemic travel and social distanc- relevant, and very much open for busi - ing restrictions. Sure, they might have ness during a time when everything is discussed supplementing with a virtual so uncertain. event, but from what we hear directly Team up with your association: from our members, they cannot replace AGMA cannot say this enough, but we that trusted, in-person handshake. are here for YOU! We are in the middle What is the cost of all this? To start, billions of dollars for the of making sure that next year’s Motion + Power Technology Expo is exhibitors, the hosting associations, the cities that are missing out going to be a safe, successful, and robust opportunity for you and on all the tourist spending, local convention staff, and so much more. your sales team to get the quality leads the show is known for. We Sales people are not just keeping their products moving, but the also have AGMA Media, where our magazines offer a variety of options work they do at events, on the road, and online truly helps local for every budget to raise brand awareness. And, lastly, we offer you communities to stay thriving. So, with all that bad news to chew on, connections to the experts throughout the world that help develop AGMA would like to offer some solutions to these pressing issues: standards, educate us on gear technology, and inform us of the latest Plan and pivot: Many sales people have been doing business a cer- trade and tariffs facing our supply chains. tain way for their whole career. Now is the time to try something new. So, sales people, you are not alone. The pressure is on for you to Talk to your sales team, brainstorm with your employees and market- bring in the money, and we know that is not easy. We understand ing department about what they already know and don’t know, and the need for unconventional tactics to push forward, and AGMA is get a baseline for how you plan to change strategies. Take a moment here to give you options. Please visit our websites to see what kind and come up with a sustainable solution for not only this year, but of services we can provide to help connect you to your customer: 2021 as well. It is never too early to start thinking about what will be www.agma.org: To see all the benefits of being an AGMA mem- open next year. And, always include other departments in the efforts ber along with how to sponsor an event. to shake it up! motionpowerexpo.com: To start planning your exhibit for 2021’s Get online: If you are not already on LinkedIn, Facebook, YouTube, in-person show. Instagram, or other social media platforms, you need to be. Real sales www.geartechnology.com and www.powertransmission.com: leads and business connections are happening every second of the To see how you can advertise or contribute as an industry writer.

August 2020 19 Upcoming Webinars

September 2, 2020 | 1–2 p.m. EDT | Free Problem of Counterfeit Imports: U.S. Government Initia- Huawei or the Highway: How New U.S. National Security tives and Next Steps for Industry to Consider Laws Aimed at China will Impact Emerging Technologies Imports of counterfeit bearing and gear products continue to present and IoT Initiatives in the Bearing and Gear Industries. challenges for our industries, raising real safety risks, undercutting consumer confidence, and harming the bottom line. This webinar Behind the headlines about a Chinese company, Huawei’s alleged will examine a range of new initiatives designed to stem the flow of violations of U.S. export control and sanctions laws are a range of U.S. counterfeit products into this country and provide practical advice government initiatives designed to address concerns over Chinese on how to fight back and enlist U.S. government resources in that technological and market dominance of emerging technologies like fight. 5G and “Internet of Things” (IoT). The Trump administration has been taking a whole of government approach to these issues, engag- November 4, 2020 | 1–2 p.m. | Free ing in new rulemaking and working closely with Congress and independent agencies such as the Federal Communications Commission Decision 2020: Inside the Trade Policy Platforms of the to craft a set of rules that will shape the direction of investment in Presidential Candidates and Prospects for U.S. Trade these technologies for years to come. This webinar will explore these Policy in 2021 issues and highlight the many pitfalls and opportunities for bearing and gear companies that rely on these technologies or plan to make Trade policy has perhaps never been more prominently featured them part of new projects and products. in the headlines and U.S. politics than it has over the past four years. This webinar will go behind the headlines to examine October 7, 2020 | 1–2 p.m. | Free where the presidential candidates and their parties stand on trade issues and what changes and new initiatives will be coming after Options and Approaches to Addressing the Continuing Election Day.

American Gear Manufacturers 20 gearsolutions.comAssociation ONGOING RECORDED VIRTUAL TRAINING Detailed Gear Design – Beyond Simple Factors. Gear Failure Analysis. Gearbox CSI: Gears Only. Online Workforce Training: Parallel Gear Inspection. Online Workforce Training: Hobbing. Online Workforce Training: Fundamentals of Gearing. The AGMA Fall Technical Meeting is Going Virtual! For 2020, AGMA has decided to make the FTM an online event so people all over the world can experience the quality presentations from the gearing experts without having to travel. FTM Virtual will be in October and will consist of 10 pre-recorded presentations and one live Q&A session with the speakers. More details will be coming out soon, so make sure to check in at www.agma.org/2020-fall- technical-meeting/ 2020 FTM VIRTUAL MEETING October 5-19, 2020: On Demand Content Available October 20, 2020: Live Q&A Sessions & Virtual Networking

For 2020, and due to the COVID-19 pandemic, AGMA is hosting the Fall Technical Meeting online. The technical experts have chosen 10 NEW! Gear Education incredible papers that will be presented by the researchers in a pre- recorded video to share with attendees. Those who sign up will have to Fit Your Needs! Virtual two weeks to watch these presentations and prepare questions for the presenters. On October 20, you will get to see and hear these present- & Live Classes Available! ers live to ask your questions and to network with other attendees! We understand that a virtual event is never the same as getting AGMA offers video training and an online workforce training series that in-person experience, but AGMA and the technical community for members and non-members. These courses are a convenient way deserve to continue this decades-old staple in the gear industry so to keep your employees learning from the computer. Visit: www. the latest research can be shared with engineers all over the world. agma.org/education/online/video-training/detailed-gear-design- Innovation does not stop because of a pandemic, so neither will we. beyond-simple-service-factors to see the course descriptions. Sign up today: www.agma.org/2020-fall-technical-meeting

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

1001 N. Fairfax Street | Suite 500 | Alexandria, VA 22314 | (703) 684-0211 | www.agma.org August 2020 21 CALENDAR OF EVENTS Whether you’re looking for technical education, networking opportunities, or a way for your voice to be heard in the standards process, AGMA has something to offer you. If you would like more information on any of the following events, visit www.agma.org or send an email to [email protected].

August 18 — Plastics Committee Meeting — WebEx August 18 –19 — AGMA Board of Directors Meeting — Alexandria, Virginia August 20 –21 — TDEC Meeting — Alexandria, Virginia August 25 — Gear Accuracy Committee — WebEx

AUGUST August 26 — Lubrication Committee Meeting — WebEx August 27 — Bevel Gearing Committee Meeting — WebEx

September 8 — Metallurgy and Materials Committee Meeting — WebEx September 10 — Nomenclature Committee Meeting — WebEx September 15 — Powder Metallurgy Committee Meeting — WebEx September 22 — Metallurgy and Materials Committee Meeting — WebEx September 24 — Bevel Gearing Committee Meeting — WebEx

SEPTEMBER September 25 — 3D Printing Committee Meeting — WebEx September 29 — Wormgearing Committee Meeting — WebEx

October 6 — Nomenclature Committee Meeting — WebEx October 8 — Gear Accuracy Committee — WebEx October 16 — Electric Drive Committee Meeting — WebEx

OCTOBER October 20 — Fall Technical Meeting Live Q&A Session — Virtual Platform

AGMA LEADERSHIP

John Cross: Chairman Zen Cichon: Innovative Rack & Gear Company ASI Drives Michael Cinquemani: Master Power Transmission Greg Schulte: Treasurer Bonfiglioli USA Greg Estell: The Estell Group LLC Michael McKernin: Chairman, BMEC Bent Hervard: CFT Gear Group at United Stars, Inc. Croix Gear & Machining Todd Praneis: Chairman, TDEC Ruth Johnston: Cotta Transmission Company, LLC Jack Masseth: Meritor, Inc. Jim Bregi: Chairman Emeritus Scott Miller: Caterpillar, Inc. EXECUTIVE COMMITTEE Doppler Gear Company Gary Neidig: ITAMCO Shawn O’Brien: McInnes Rolled Rings BOARD OF DIRECTORS Robert Rye: Cincinnati Gear Co. Matt Croson: President Amir Aboutaleb: VP, Technical Division Eric Van Rens: Schafer Industries STAFF Jenny Blackford: VP, Marketing Sara Zimmerman: Sumitomo Drive Technologies

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

22 gearsolutions.com August 18 — Plastics Committee Meeting — WebEx August 18 –19 — AGMA Board of Directors Meeting — Alexandria, Virginia August 20 –21 — TDEC Meeting — Alexandria, Virginia YOU’VE GOT THE PRODUCTS. August 25 — Gear Accuracy Committee — WebEx August 26 — Lubrication Committee Meeting — WebEx August 27 — Bevel Gearing Committee Meeting — WebEx YOU’VE GOT THE SERVICES. September 8 — Metallurgy and Materials Committee Meeting — WebEx September 10 — Nomenclature Committee Meeting — WebEx September 15 — Powder Metallurgy Committee Meeting — WebEx NOW, LET US SHARE YOUR STORY. September 22 — Metallurgy and Materials Committee Meeting — WebEx September 24 — Bevel Gearing Committee Meeting — WebEx September 25 — 3D Printing Committee Meeting — WebEx Gear Solutions wants to make sure the best September 29 — Wormgearing Committee Meeting — WebEx possible audience knows your company. October 6 — Nomenclature Committee Meeting — WebEx Through our print, online, and social media October 8 — Gear Accuracy Committee — WebEx October 16 — Electric Drive Committee Meeting — WebEx presence, our experienced staff can get your October 20 — Fall Technical Meeting Live Q&A Session — Virtual Platform message to an industry that wants to know what you can do.

To learn more, contact national sales manager Dave Gomez at [email protected] or call 800.366.2185 ext. 207

August 2020 23 E. BUDDY DAMM STEEL SOLUTION SCIENTIEST  MATERIALS  MATTER TIMKENSTEEL CORPORATION

Future of gear design relies on overcoming present Improved production efficiency through relevant specs for tomorrow. Speed is a huge opportunity. Design engineers of the future should optimized machinability or heat-treat be able to do as much virtually as possible, without relying on tra- response can result in lower ditional, empirical validation that can take years to achieve. Tools such as advanced modeling, coupled with expertise and data about costs – and more contract wins. the performance of materials in applications, are just the beginning of the spectrum when enhancing the speed of design to production. ncreasing application demands and the need for higher perfor- It’s not just what we know today. It’s what we know about what we Imance mean the future is coming fast for gear designs. The next don’t know, and how fast we learn what we need to know, then make generation of gear engineers needs to be ready to tackle these ever- that know-how commercially relevant and successfully implement growing challenges. Here are a just a few ways we believe “Materials those solutions. A supplier’s depth of knowledge allows a quantita- Matter” for the gear of the future. tive relationship between metrics and end-application design limits. Design is relevant. More than ever before, customized solutions And, a supplier’s willingness to speak in a design language — or using a combination of cleaner steels and specific alloy design to get relating specs and standards to ways of characterizing — is a tre- the results you need will be critical. Enhanced performance charac- mendous asset in design. Together, these factors will reduce costs teristics as a result of fatigue failure resistance, such as improved and increase efficiency. fatigue life and power densification, depend on it. New grade development in this area will take these factors even further. Supply chain collaboration provides greater benefits. Having easy access from the material all the way through to the end product — from steel supplier to gear cutter, heat- treater to transmission builder — offers extreme efficiencies in process flow. As the lines between engineering disciplines blur, successful gear steel suppliers of the future, such as TimkenSteel with its application and modeling knowledge and broad offering of products and value-added services, provide a wider variety of solutions, from beginning to end, with deep knowledge across the entire supply chain. Further, gear designers know winning the next contract often means having the best total cost footprint. Working with suppliers who can provide an understanding of how the chosen steel affects manufacturing operations is invaluable. Improved production efficiency through The next generation of gear designers must achieve never-before- optimized machinability or heat-treat response can result in lower seen levels of performance. As we head into a world with longer life, costs — and more contract wins. increased power and enhanced efficiency as the norm, overcoming Specifications must become more meaningful. Current standards are the material uncertainty that exists today will help build the path simply not specific enough to address the higher-performance needs to get us there. Ultimately, gear designers need to expect more from of future applications. Systems today are designed with conservatism, their steel suppliers; they must have a valued partnership in which using paradigms that are decades old, and even wasteful. Enhanced steel suppliers understand where new developments could occur and performance requires more design-relevant information, and that help gear-design engineers to take the greatest advantage of them. means partnering with a supplier who will meet specs today, recognizes the challenges ahead, and can help to design and meet the This article first appeared in the July 2018 issue of Gear Solutions.

ABOUT THE AUTHOR E. Buddy Damm is a steel solutions scientist at TimkenSteel. Email him at [email protected]. Learn more at www.timkensteel.com.

24 gearsolutions.com YOUR SOURCE FOR GEAR INDUSTRY NEWS

Gear Solutions magazine has been the JOIN THE GEAR SOLUTIONS most trusted source for information COMMUNITY and technical knowledge in the gear FOR ONLY $ manufacturing industry for more than 350 PER YEAR 15 years. Each issue, Gear Solutions offers its readers the latest, most valuable content available from companies, large and small, as well as critical thoughts on what this information means for the future of the gear manufacturing industry. Best of all, it’s free to you. All you need to do is subscribe. On GearSolutions.com, we have paired our vast technical archives with the latest web technologies

GEAR SOLUTIONS MAGAZINE MAGAZINE SOLUTIONS GEAR to develop the most efficient, streamlined, user-

friendly web experience in the gear industry.

Your Resource for Machines, Services, and Tooling for the Gear Industry MAGAZINE SOLUTIONS GEAR

Your Resource for Machines, Services, and Tooling for the Gear Industry ISSUE FOCUS

Cutting Tools | Workholding

INCREASING STATIC FRICTION WITH LASER WITH STATIC FRICTION INCREASING INCREASING ISSUE FOCUS

THE ROOT CAUSE FOR GEAR NOISE EXCITATION NOISE GEAR FOR CAUSE ROOT THE Bevel Gears | Plastic Gears GEAR SOLUTIONS MAGAZINE STATIC FRICTION WITH LASER THE ROOT CAUSE FOR

COMPANY GEAR NOISE

Your Resource PROFILEfor Machines, Services, and Tooling for the Gear Industry

WEILER ABRASIVES EXCITATION

COMPANY PROFILE

GEAR TOOTH STRENGTH ANALYSIS OF HIGH PRESSURE ANGLE CYLINDRICAL GEARS ISSUE FOCUS PISELLI ENTERPRISES APRIL 2019 APRIL Gear Shaping | Gear Hobbing APRIL 2019

GEAR TOOTH STRENGTH ANALYSIS OF gearsolutions.com DECEMBER 2018 DECEMBER HIGHSUBSCRIBE PRESSURE FOR FREE ANGLEwww.gearsolutions.com CYLINDRICAL GEARS August 2020 DECEMBER 25 COMPANY gearsolutions.com 2018 PROFILE WOLVERINE BROACH CO. INC.

JUNE 2018 gearsolutions.com

JUNE 2018 BRIAN DENGEL TOOTH  TIPS GENERAL MANAGER KHK-USA

What, precisely, is my gear made of? Almost 90 percent of the steel produced is Stainless steels have a minimum chromium content of 11 percent and are an alloy of many trace elements including nickel, manga- carbon steel, but alloy steel, stainless steel, nese, silicon, phosphorus, sulfur, and nitrogen. They are subdivided or tool steel are possibilities as well. into ferritic stainless steels, which are magnetic, and austenitic stainless steels, which are nonmagnetic. The austenitic stainless steels are he building blocks for all materials are microstructures known as designated as 300 series stainless steels, whereas the ferritic stainless Tatoms. Whether the material in question is a plastic, a metal, or steels are designated as the 400 series stainless steels. even your skin, they each consists of atoms co-existing in a peaceful Tool steels are the final family of steel. They are steel alloys with dance known as bonding. Each atom consists of electrons, protons, traces of cobalt, molybdenum, tungsten and/or vanadium. These ele- and a nucleus. When a group of identical atoms are grouped togeth- ments add heat resistance and durability to the steel. er, they form an element. Since the late 1600s when the concept of There is one additional alloy of steel that has yet to be developed. atomic structure was first discussed, a total of 118 unique elements It is frequently requested by customers for use in their gear design. have been identified. It is from these elements that we can manu- This alloy is known as unobtainium. This material is extremely light- facture gears. Researchers have determined that the ten most populous elements on Earth are: oxygen, silicon, aluminum, iron, calcium, sodi- um, magnesium, potassium, titanium, and hydrogen. Some of these elements exist in their natural state and others join together with other elements to form compounds. It is the compounding of elements that create the materials that we use every day. Carbon is an element that is the foundation of all cellular life. It has unique properties that allow it to compound with nitrogen, hydrogen, and oxygen to form the building blocks of plant and animal cells. Carbon is also a valuable element for gearing as it can be compounded with iron to form steel. Steel is an alloy of iron, carbon, and other trace elements. It is generally accepted that there are four basic types of steel: carbon steel, alloy steel, stainless steel, and tool steel. Almost 90 percent of the steel produced is carbon steel. The chart included here details the steel classification system of AISI and SAE. The first two digits of the steel designation are determined by the basic structure of the steel, and the last two digits Steel is an alloy of iron, carbon, and as represented by the XX in the table represent the percentage of other trace elements. It is generally carbon in the steel. For example, a 1020 carbon steel has a 0.20 percent carbon content, whereas a 1045 carbon steel has a 0.45 percent accepted that there are four basic carbon content. Carbon steels can be further classified into mild steel, medium types of steel: carbon steel, alloy carbon, and high carbon steel. Mild steel has a less than 0.30 percent carbon content. High carbon steel has a carbon content greater than steel, stainless steel, and tool steel. 0.60 percent, and the medium content steels fall in between. Alloy steels such as 4140 contain additional elements such as weight, has a hardness greater than that of a natural diamond, has aluminum, chromium, copper, and/or nickel. These other elements a co-efficient of friction of 0.001, is dimensionally stable in all envi- when alloyed with the iron and carbon create steels which are ronments, neither corrodes nor rusts, it is easily machinable and a stronger, easier to machine, and offer more corrosion resistance raw material cost of $0.01 per pound. Once invented it will make all than plain carbon steel. other steels obsolete and will greatly improve gear train efficiency.

26 gearsolutions.com AISI/SAE Designation Steel/Alloy Chemical Composition 10XX Carbon steels Plain carbon, Mn 1.00% max 11XX Resulfurized free machining 12XX Resulfurized / rephosphorized free machining 15XX Plain carbon, Mn 1.00-1.65% 13XX Manganese steel Mn 1.75% 23XX Nickel steels Ni 3.50% 25XX Ni 5.00% 31XX Nickel-chromium steels Ni 1.25%, Cr 0.65-0.80% 32XX Ni 1.75%, Cr 1.07% 33XX Ni 3.50%, Cr 1.50-1.57% 34XX Ni 3.00%, Cr 0.77% 40XX Molybdenum steels Mo 0.20-0.25% 44XX Mo 0.40-0.52% 41XX Chromium-molybdenum steels Cr 0.50-0.95%, Mo 0.12-0.30% 43XX Nickel-chromium-molybdenum steels Ni 1.82%, Cr 0.50-0.80%, Mo 0.25% 47XX Ni 1.05%, Cr 0.45%, Mo 0.20-0.35% 46XX Nickel-molybdenum steels Ni 0.85-1.82%, Mo 0.20-0.25% 48XX Ni 3.50%, Mo 0.25% 50XX Chromium steels Cr 0.27-0.65% 51XX Cr 0.80-1.05% 50XXX Cr 0.50%, C 1.00% min 51XXX Cr 1.02%, C 1.00% min 52XXX Cr 1.45%, C 1.00% min 61XX Chromium-vanadium steels Cr 0.60-0.95%, V 0.10-0.15% 72XX Tungsten-chromium steels W 1.75%, Cr 0.75% 81XX Nickel-chromium-molybdenum steels Ni .30%, Cr 0.40%, Mo 0.12% 86XX Ni .55%, Cr 0.50%, Mo 0.20% 87XX Ni .55%, Cr 0.50%, Mo 0.25% 88XX Ni .55%, Cr 0.50%, Mo 0.35% 92XX Silicon-manganese steels Si 1.40-2.00%, Mn 0.65-0.85%, Cr 0-0.65% 93XX Nickel-chromium-molybdenum steels Ni 3.25%, Cr 1.20%, Mo 0.12% 94XX Ni 0.45%, Cr 0.40%, Mo 0.12% 97XX Ni 0.55%, Cr 0.20%, Mo 0.20% 98XX Ni 1.00%, Cr 0.80%, Mo 0.25%

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

August 2020 27 D. SCOTT MACKENZIE, PH.D., FASM HOT SENIOR RESEARCH SCIENTIST–METALLURGY  SEAT QUAKER HOUGHTON INC.

Fracture mechanics and fatigue crack growth Fracture mechanics and fracture toughness measurements can be used directly in design, becoming an enormously useful tool for determining the life of a component.

n the last article, we talked about fracture mechanics, and the Imethod of fracture toughness testing using fracture mechanics. In this article, we are going to discuss how fracture toughness can be used to solve fracture and fatigue problems. In traditional fatigue analysis, stress concentration factors are Fracture Mechanics Notch Analysis used to calculate fatigue life. These stress concentration factors are holes or notches that locally increase the stress. In fracture mechanics, Fundamentals Elastic energy Stress concentration the stress intensity factor is calculated for a given crack and compared equivalent stress concentration (K) to the critical value, KIc, critical stress intensity factor. If the stress intensity factor is larger than the critical stress intensity factor, then Applied theory Linear elastic theory Linear elastic theory the crack will propagate catastrophically. A comparison of traditional elastic-plastic fatigue analysis and fracture mechanics is shown in Table 1. behavior From Paris [2], the propagation of a crack follows the basic form of: Principles σ√a = constant Size effect Correction for plastic zone at crack tip

where C and N are material constants, and Table 1: Comparison of Traditional Notch Analysis and Fracture Mechanics in Fatigue Analysis [1].

da/dN is the crack growth in mm/cycle. The values of C and N can vary due to heat treatment and condition of material, in general, so equations that are accepted [3] For martensitic steels, this is:

For ferrite-pearlite steels:

And for aluminum [4]:

Figure 1: Fatigue crack propagation rates for 3” thick 7050-T7451 aluminum plate.

An example of a crack growth rate curve is shown in Figure 1 [5]. In theory, if KI is less than KIc the crack will not propagate. If KI These basic equations can be used to calculate fatigue crack is equal to KIc the crack will propagate catastrophically. This can be growth from some basic flaw size a to the critical flaw size ac, where used to calculate a critical flaw size (discussed later). The calcula- catastrophic crack propagation can occur. The first thing that is tion of the stress intensity factor K is usually done currently using needed is an understanding and relationship for the stress inten- finite element analysis. Compilations of stress intensity factors are sity factor, K. available in texts on fracture mechanics [6] or in numerous different In static loading, the stress intensity factor for a small crack handbooks [7]. can be expressed as a function of the stress, crack length a, and The basic method used for calculating fatigue life of a component geometry, b: consists of the following: Find stress intensity factor for the geometry of interest. Determine critical flaw size where Kmax = KIc . 28 gearsolutions.com Rearranging:

Since this is a pearlitic steel, for this example, c = 3.6 x 10-10 and n = 3.0. The exact coefficients should be verified for the alloy and loading conditions. Many of the materials are tabulated in [5]. The stress intensity factor for this loading is:

Substituting and integrating, with acr (0.21”) as the upper bound and the lower bound as the smallest detectible flaw size a (0.020”), the following integral is established:

There will be an incubation time that is dependent on the material, as well as some plasticity at the crack tip. However, this method is used extensively in aerospace to determine inspection cycles, and to establish life of a component. CONCLUSIONS In this brief article, some basic principles of fracture mechanics were Figure 2: Infinite plate with uniform axial loading. Flaw size is equal to 2a. illustrated, as well as how fracture mechanics and fracture toughness measurements can be used directly in design. This is an enor- Verify that the linear elastic fracture mechanics (LEFM) require- mously useful tool for determining the life of a component. ments are fulfilled. It is hoped that this series of articles on the application of mechan- Integrate the Paris law with the integration bounds from the ical testing has been informative and useful. In the next series of assumed or detectible flaw size to the critical flaw size. articles, we will be discussing the various non-destructive testing Solve for the number of stress cycles until failure. techniques to detect flaws. Should you have any comments or ques- In this example, we have a pearlitic steel, with a yield strength tions regarding this article, or have suggestions for further articles, of 165 ksi, with a fracture toughness, KIc of 65 ksi-√in. An infinite please contact the writer or editor. plate with uniform axial loading (Figure 2) is loaded to 80 ksi, then loading released back to zero. From non-destructive testing, the REFERENCES smallest flaw that the technique can detect is 0.040” in diameter, [ 1 ] G. Jacoby, “Application of Microfratography to the Study of Crack Propagation or a = 0.020”. Under Fatigue Stress,” 1966. [ 2 ] P. C. Paris and F. Erogan, “A Critical Analysis of Crack Propagation Laws,” DETERMINATION OF THE CRITICAL FLAW SIZE Journal of Basic Engineering, Transactions of the American Society of The first thing necessary to determine the Critical Flaw Size, acr , is Mechanical Engineers, pp. 528-534, 1963. to remember that [8]: [ 3 ] S. T. Rolfe and J. M. Barsom, Fatigue and Fracture Control in Structures, Englewood Cliffs, NJ: Prentice-Hall, 1977.

Rearranging: [ 4 ] N. E. Frost, K. J. Marsh and L. P. Pook, Metal Fatigue, London, England: Oxford University Press, 1974.

[ 5 ] Department of Defense, Metallic Materials and Elements for Aerospace Vehicle Structures, Department for Defense Handbook, 2003.

At this loading, a flaw equal to the critical flaw size,a cr , will result [ 6 ] T. L. Anderson, Fracture Mechanics Fundamentals and Applications, Boca (in theory) of the material failing catastrophically. Raton FL: CRC Press, 1995. Stress intensity factor will change as the geometry and type of [ 7 ] H. Tada, P. C. Paris and G. R. Irwin, The Stress Analysis of Cracks Handbook, loading changes. The specific condition should be evaluated using New York: ASME Press, 2000. the proper geometry and load condition [9]. [ 8 ] G. R. Irwin, “Fracture,” in Encyclopedia of Physics, vol. VI, Heidelberg, DETERMINATION OF FATIGUE LIFE Springer, 1958, p. 561. From Paris [2], the crack life relationship or Paris Law, is: [ 9 ] J. W. Faulpel and F. E. Fisher, Engineering Design, New York: Wiley, 1981.

ABOUT THE AUTHOR D. Scott MacKenzie, Ph.D., FASM, is senior research scientist-metallurgy at Quaker Houghton Inc. For more information, go to https://home.quakerhoughton.com/

August 2020 29 ISSUE GEAR DESIGN / INVOLUTE GEARS FOCUS

RAPID AND PRECISE MANUFACTURING OF SPECIAL INVOLUTE GEARS FOR PROTOTYPE TESTING

Printed with permission of the copyright holder, the American Gear Manufacturers Association, 1001 N. Fairfax Street, Suite 500, Alexandria, Virginia 22314. Statements presented in this paper are those of the authors and may not represent the position or opinion of the American Gear Manufacturers Association. (AGMA) This paper was presented October 2019 at the AGMA Fall Technical Meeting in Detroit, Michigan. 19FTM20

30 gearsolutions.com Even though the high production times per test gear compared to gear hobbing can be compensated by the elimination of long design and procurement times for special production tools, a suitable method is available for the fast, precise, and cost-efficient production of special gears for prototype tests.

By CHRISTIAN WEBER, M.Sc., DR.-ING. THOMAS TOBIE, and PROF. DR.-ING. KARSTEN STAHL

ue to the steadily increasing demands on the occur during operation are decisive factors in deter- power density of mechanical transmissions, mining the gear design. In combination with the gears with special geometries are increasingly properties and characteristic values of the materials D coming into focus and, therefore, the need for and lubricants used, they determine the load carrying short-term availability of prototypes. Such special gear capacity of a set of gears and thus the size and weight designs are, e.g., asymmetrical gears with different of the entire gearbox. normal pressure angles on the drive and coast flank. Many different approaches are used to increase the These are particularly suitable for use in gearboxes load carrying capacity and thus the power density of with preferred driving direction, whereby the loaded gearboxes. For example, existing material and heat- flank can be optimized with regard to load carrying treatment concepts can be optimized or high- perfor- capacity. With symmetrical gears with normal pres- mance materials and heat-treatment processes adapt- sure angles in the range of an = 20°, standardized cal- ed to them can be used [4, 7, 15, 18, 25]. Furthermore, culation methods for gear design have been available an optimized surface treatment, such as vibratory for decades — mainly theoretical numerical investiga- finishing or shot peening for improved residual stress tions have been carried out on asymmetrical gears so conditions after completion of the heat treatment can far. For the qualification of any such designed asym - further increase the load carrying capacity of gears metrical gear geometry with increased load carrying [5, 8, 14, 26]. capacity potential for use in industrial practice, howev- The geometric shape of the gear teeth and the er, reliable load carrying capacity values are required. tooth root curvature are important influencing fac- Therefore, according to the current state of the art, tors on the level of the occurring loads. For power- prototype tests are indispensable to determine the transmitting gear drives, nowadays almost exclusively actual gear strength. involute gears with standardized reference profiles At the Gear Research Centre (FZG), such load capac- (symmetrical tooth form with pressure angle an ≈ 20°) ity investigations are carried out using back-to-back are used. These usually have a tooth root fillet that test rigs and pulsator test rigs. The design and pro- corresponds to a trochoid. In the literature, there are curement of special tools for the production of such various approaches for the optimization of the tooth prototype gears is often time-consuming and expen- root geometry regarding an increased tooth root bend- sive. In this paper, an alternative method for a fast ing strength, compare [6, 13, 20, 21, 22]. and cost-efficient production of asymmetric gears Furthermore, in a large number of gear applica- for prototype tests is presented. The focus is on the tions with a driving direction that is dominant with grinding process from a full blank test specimen. This regard to the transmitted torque, e.g. in vehicle trans- process was applied at the FZG in cooperation with missions as well as in wind power and crane systems, Liebherr-Verzahntechnik GmbH in order to produce gears with alternative pressure angles or asymmetri- asymmetrical test gears for experimental investiga- cal gears are increasingly being considered in order tions of the tooth root bending strength. to exploit the resulting advantages in tooth root load Very good results were achieved with regard to gear carrying capacity. This development is favored by new quality and shape accuracy, especially in the tooth manufacturing processes. In the following, the design root area, which is then investigated. The results of of asymmetric gears as well as the manufacturing this paper show therefore a suitable method for the possibilities of prototype gears for the experimental fast, precise, and cost-efficient production of special investigation of the load carrying capacity of such pro- gears for prototype tests. totype gears will be discussed in more detail. 1 INTRODUCTION 2 GEARS WITH ASYMMETRIC TOOTH SHAPE The Hertzian contact pressure at the tooth flank and By using alternative special geometries, the load car- the tooth root bending stresses in the root fillet that rying capacity of gears can be improved and thus the

August 2020 31 power density of gears can be increased. Enlarging the normal pressure angle thus reduces the stresses in the tooth root and, at the same time, reduces the maximum pressure on the tooth flank. Disadvantages from the changed geometry can be compensated by an optimized design of the drive and coast flank, i.e. by an asymmetrical design of the teeth. The potential of such gear geometries, especially for increasing the tooth root load carrying capacity, has already been demon- strated many times on the basis of mainly theoretical work, compare [2, 3, 12]. However, for a reliable application of special involute gears in industrially running transmissions, a comprehensive and con- Figure 1: Lever of the acting force on symmetric and on asymmetric teeth [17] (left and center) and tooth root chord at the critical section of asymmetric teeth [16] (right). firmed identification and verification of the load carrying capacities are needed for Denomination Symbol Unit P-m4-2020 P-m4-2818 P-m4-3015 P-m4-4010 such toothings. This requires an upgrade of (reference) existing tooth root load carrying capacity Module mn mm 4 calculation methods as described in [24], so the specific characteristics of special Number of teeth z - 48 involute gears, as well as experimental test Pressure angles αn,bel/ αn,unb ° 20/20 28/18 30/15 40/10 results, must be taken into consideration. At the Gear Research Centre (FZG), a cor- Face width b mm 15 responding calculation approach was devel- tip diameter da mm 202,0 202,0 202,0 199,0 oped to determine the tooth root stresses occurring on gears with alternative normal Table 1: Main nominal test gear geometry. pressure angles or asymmetrical tooth profiles [23]. According to FZG/Langheinrich according to Langheinrich [16]. [23], the analytical determination of the tooth root stress for alter- sFn’ is the tooth root chord at the critical section, according to native tooth geometries is possible by a relatively simple adaptation Langheinrich [16]. of the standardized calculation steps according to ISO 6336 - Part 3 aFen is the load direction angle relevant to direction of applica- [10]. The following equations from the existing ISO 6336 -Part 3 [10] tion of load at the outer point of single pair tooth contact. standard were modified to extend them to alternative gear geom- YSa is the pressure angle factor (tooth root). etries with a modified pressure angle. The modified form factor The required tooth root thickness of gears with changed pressure YF’ and the modified stress correction factor YS’ in Equation 1 are angles sFn’ in the calculation of the nominal tooth root stress can be functions of the adjusted relevant bending moment arm hFe’ and determined by the mean value of the tooth root thicknesses. This the adjusted tooth root chord at the critical section sFn’. approach for asymmetric teeth is already described in ISO 10300 – Part 3 [11] for bevel gears and is shown at right in Figure 1. Equation 1 The bending moment around the point N in the tooth root of asymmetric gears can be determined by shifting the acting force along its line of action. As basis for the relevant bending moment Equation 2 arm hFe’ in the tooth root area, the tooth root thickness is used for asymmetric as well as for symmetric gears. It is determined with the Equation 3 tooth root fillet of the loaded f lank. This principle is shown in Figure where 1 on the left for symmetric gears and in the middle for asymmetric sF0 is the nominal tooth root stress. gears respectively. The diameter dFn,bel is determined according to Ft is the (nominal) transverse tangential load at reference cyl- ISO 6336 – Part3 [10]. inder per mesh. In addition, the stress correction factor YS’ in Equation 3 has been b is the face width. extended by the pressure angle factor YSa. This factor takes into mn is the normal module. account the effects on the tooth root stresses, which are caused by YF’ is the tooth form factor for the influence on nominal tooth teeth with normal pressure angles an ≠ 20° at the loaded (an,bel) and root stress with load applied at the outer point of single pair tooth unloaded (an,unb) tooth flank. The approach for calculating the pres- contact, according to Langheinrich [16]. sure angle factor YSa is shown in the analytical simplified Equation 4. Y ’ is the stress correction factor for the conversion of the S Equation 4 nominal tooth root stress, determined for application of load at the outer point of single pair tooth contact, to the local tooth root stress, where according to Langheinrich [16]. YSa is the pressure angle factor (tooth root). Yb is the helix angle factor (tooth root). an,bel is the pressure angle at the loaded tooth flank. hFe’ is the bending moment arm for tooth root stress relevant an,unb is the pressure angle at the unloaded tooth flank. to load application at the outer point of single pair tooth contact, F1/F2 are auxiliary variables. 32 gearsolutions.com 3 EXPERIMENTAL INVESTIGATION OF THE TOOTH ROOT BENDING STRENGTH

3.1 TEST RIG AND TEST METHOD Experimental investigations to determine the tooth root bending strength are usually time-consuming and costly. However, this is often indispensable for the validation of theoretical investigations. At the FZG, the experimental investigation of the tooth root bending strength of involute external spur gears is usually carried out in pulsator test rigs. In Figure 2, an example of the schematic design of an electromagnetic resonance pulsator (system Roell-Amsler) and the typical test configuration are shown. The pulsator test rig essentially consists of a machine frame to accommodate the testing device, a load cell, and the test gear. As shown schematically in Figure 2, the test gear is clamped symmetrically between two clamping jaws. A special device ensures the force application point on the tooth flank can be set precisely and be reproduced for every test of a series when clamping the test wheels. Deviations in the flank angle can be compensated by fine adjustment of the clamping jaws so an even load distribution over the tooth width can be ensured. By means of the mid-load actuator and the Figure 2: Schematic test configuration for tooth root bending tests in a pulsator test rig. mid-load springs, the gear to be tested is pre- loaded with a static load. This prevents the For external involute gears, the auxiliary variables F1 and F2 have gear from falling out during the test run. The dynamic load is then the values 78 and 852 respectively. It can be seen that both calculat- mechanically generated by an electronically controlled excitation ing methods according to Langheinrich [17] and ISO 6336 – Part3 magnet and transmitted via the pole springs to the vibrating traverse [10] give the same result for symmetric involute gears with pressure and the test gear. The test conditions for each test are continuously angle an = 20°. The determination of the auxiliary variables F1 and F2 recorded and logged by PC. in this calculation approach according to Langheinrich [16] is based The main advantage of this test method is that several test points on variational calculations on more than 2,000 external spur gear can be determined for each test gear. Depending on the gear geom- geometries of different normal pressure angle combinations, num- etry to be tested, only between three and 10 test gears are required ber of teeth, profile modification factors, and tool parameters. These to determine a complete S-N-line with up to 25 test points for char- were evaluated with regard to the tooth root stresses occurring in acterizing the tooth root load carrying capacity. Furthermore, the each case. For each variant, the nominal tooth root stress was deter- running times per test point are relatively short due to the high mined using both the numerically Finite Elements (FE) Method and achievable test frequencies. Altogether, this test method makes it the analytical calculation approach according to ISO 6336 - Part 3 [10]. possible to carry out the experimental verification of the tooth root For asymmetric pressure angle combinations, the modified calcula- bending strength of a gear geometry comparatively quickly and cost- tion method (see Equations 1-4) according to Langheinrich [16] was effectively. used. The results of the analytical calculations were then compared with the FE calculations. 3.2 REQUIREMENTS FOR TEST GEARS The test results of first experimental investigations on an FOR TOOTH ROOT BENDING TESTS asymmetric gear geometry with pressure angle combination an = The tooth root load carrying capacity of spur gears is significantly 28°/18° show a good agreement with this new analytical calculation influenced by the geometry of the tooth root. Therefore, it is neces- approach [24]. sary to consider this geometry as accurately as possible when car- Currently at the FZG, further extensive experimental investiga- rying out experimental investigations to determine the tooth root tions are conducted to validate the standard-compliant calculation bending strength. As described by Hyatt et al. [9], in contrast to the approach according to Langheinrich [16]. Three different, asymmetri- tooth flank, the exact geometry in the area of the tooth root is typical gear geometries are considered in comparison to a symmetrical cally not tolerated and is generally not subject to standardized toler- reference variant. The main geometry data of these gears are shown ance. For this reason, the actual tooth root geometry is determined in Table 1. by means of a contour scan on a Klingelnberg P40 gear measuring The production of these asymmetric test gears faced challenges machine at the FZG for all experimental investigations and com- discussed in the following. pared with the designed nominal geometry. This is illustrated in

August 2020 33 Figure 3 for the hobbed reference test variant P-m4-2020 from Table 1. As can be seen in Figure 3, there are slight deviations both between the two measured test gears and between the gear geometry actually manufactured and originally designed. As described by Nigade and Wink [19], such deviations between designed test gear geometry and test gear geometry produced by gear hobbing can lead to considerable deviations of up to 22 percent between actual tooth root stresses occurring in operation and those assumed during the Figure 3: Comparison of contour scans of two different test gears and the design. For this reason, good contour accuracy in the tooth root area originally designed gear geometry (hobbed reference variant P-m4-2020). must be ensured, especially when manufacturing test gears for the experimental validation of the tooth root load carrying capacity of new tooth respectively tooth root geometries. 4 MANUFACTURING OF PROTOTYPE GEARS FOR TOOTH ROOT BENDING TESTS As described in Section 3.1, only a few test gears per test variant are required for the experimental determination of the tooth root load carrying capacity in the pulsator test rig, depending on the test gear geometry. However, even this can be a problem if, as shown in Table 1, several different, new gear geometries are to be investigated experimentally for which no gear hobbing tools have been available so far. In this case, the purchasing of new gear hobbing tools can be disproportionately expensive and also time-consuming, so an alternative manufacturing option should be considered. As already mentioned, almost all spur gears produced in series production today are manufactured by gear hobbing. This manufacturing process has economic advantages when manufacturing many gears of the same geometry. But the design and procurement Figure 4: Grinding setup of a test gear from a full blank test specimen. of special tools for the production of only a few prototype gears may be time-consuming and expensive. Therefore, alternative manufacturing processes come to focus. Bouquet et al. [1] give an overview of alternative manufacturing methods of test gears for prototype tests and evaluate these with regard to manufacturing effort, manufacturing quality, and process time. The following manufacturing processes are considered: Milling (manufacturing on a 5-axis milling machine with stan- Figure 5: Comparison of a contour scan of a test gear and the originally designed dard end and ball mills). gear geometry (variant P-m4-2818). Wire-EDM. Selective laser melting. The authors came to the conclusion that of these, milling is the most promising process for the rapid production of prototype gears [1]. The reasons given for this are the high flexibility and good surface quality of the gears produced. Contour accuracy is described as good for the milling manufacturing process. The two other manufacturing methods are described as not practical due to the current Figure 6: Comparison of a contour scan of a test gear and the originally designed state of the art. gear geometry (variant P-m4-3015). Since no 5-axis milling machine was available on the FZG at the time the asymmetrical gears listed in Table 1 were manufactured, the gears were instead ground from a full blank test specimen on the Liebherr LGG 280 gear grinding machine available at the Institute. This was done in close cooperation with Liebherr-Verzahntechnik GmbH, which provided software updates for asymmetric gears as well as for full grinding and technical support. The grinding-setup Figure 7: Comparison of a contour scan of a test gear and the originally designed for a test gear of the variant P-m4-3015 (see Table 1) from a full blank gear geometry (variant P-m4-4010). test specimen is shown in Figure 4. The production of the test gears by grinding into solid material drive and coast flank and the associated different cutting speeds on took place in a discontinuous profile form grinding process before both flanks, the correct adjustment of the grinding parameters such the heat treatment of the material (18CrNiMo7-6). Due to the geo- as speed rate and sharpening cycle must be ensured. Otherwise, a metrically indeterminate cutting edge of the grinding wheel, many significant change in the flank surface can occur, particularly on the possibilities are realizable with regard to the geometric design of the f lank with a smaller normal contact angle, as a result of an increased gears. This applies both to the tooth flank geometry and to the tooth temperature input. The pure machining time on the grinding root geometry. However, due to the different pressure angles on the machine of approximately 240 minutes per test gear is significantly

34 gearsolutions.com for each test variant. Figures 8-10 show this comparison graphically by means of the contour scans determined on three different test gears for each variant. Here, too, there is very good consistency within the individual test gear geometries with regard to contour accuracy. It can therefore be assumed that the manufacturing process is very reproducible within Figure 8: Comparison of contour scans (offset on the left for better visibility, one production batch. stacked on the right) of three different test gears (variant P-m4-2818). Finally, the manufacturing accuracy on a single test gear was also examined. For this purpose, three contour scans evenly distributed over the circumference were made on a test gear of the test geometry P-m4-3015 and compared with each other. This is shown in Figure 11. Here, too, there is very good contour accuracy, which is an indica- tor for a favorable choice of the specified grinding parameters. Altogether, the production process “grinding into solid material” Figure 9: Comparison of contour scans (offset on the left for better visibility, can be assumed to have a very high production quality with a reason- stacked on the right) of three different test gears (variant P-m4-3015). able choice of process parameters and thus a good suitability for the production of test gears for prototype tests. 6 COMPARISON TO OTHER MANUFACTURING PROCESSES FOR GEAR PROTOTYPES Since the gears considered in this paper (see Table 1) were produced exclusively by grinding into the solid material, a comparison with Figure 10: Comparison of contour scans (offset on the left for better visibility, other methods is made on the basis of the test results of Bouquet et stacked on the right) of three different test gears (variant P-m4-4010). al. [1], see Section 4. It should be mentioned here that Bouquet et al. [1] consider a different gear geometry. This is a spur gear of size mn = 2.12 mm with a number of teeth of z = 36 and a tooth width of b = 31.5 mm. Since the tooth width is about twice as large as that of the gears ground to the solid material, only half the production time is assumed for the manufacturing processes described by Bouquet et Figure 11: Comparison of contour scans (offset on the left for better visibility, al. [1] in the comparative analysis. Furthermore, only the machining stacked on the right) of three different teeth evenly distributed over the steps defining the tooth geometry with a comparable surface rough- circumference of the same test gear (variant P-m4-3015). ness are used to determine a comparative machining time. The results of this comparison are shown in Table 2. Manufacturing process Machining time Shape accuracy Flexibility It can be seen that the production of gear prototypes by grinding into full mate- Grinding into solid material 240 min ++ ++ rial at better contour accuracy requires Milling 1 240 min + ++ a machining time comparable to that of milling. However, it should also be noted Wire-EDM 1 500 min ++ - that according to Bouquet et al. [1] the Selective Laser Melting 1 495 min -- ++ machining times refer to a gear geometry 1 Data from Bouquet et al. [1] with 25 percent fewer teeth and only half the size regarding the normal module mn. Table 2: Comparison between different manufacturing processes. Especially for the manufacturing processes milling and selective laser melting, the pro- higher than the cycle time of a comparable test gear in the hobbing duction time for the gear geometry that has been ground into full process. However, production can be initiated at short notice with material would be increased even further. a short lead time to machine setup. Long procurement times for Also as mentioned in Section 4, the two manufacturing processes specially designed production tools are eliminated. wire-EDM and selective laser melting are described as not practical due to the current state of the art [1]. 5 RESULTS OF THE TEST GEARS GRINDED INTO FULL MATERIAL 7 CONCLUSION In the following, contour scans of the manufactured test gears as Three different gear geometries with asymmetric tooth shapes were described in section 3.2 are shown. First of all, Figures 5-7 show the manufactured by grinding into solid material (18CrNiMo7-6) for comparison between the originally designed test gear geometry and future investigations on the tooth root strength on a gear grinding the actual test gear geometry manufactured by grinding into full machine of the type LGG 280 available at the Institute. The exten- material for each asymmetric variant from Table 1. sive geometrical comparisons show a very good contour accuracy It can be seen that there is very good contour accuracy between for these gears compared to the originally designed gear geometry the designed and manufactured gear geometry for all of the three as well as within one test gear series. Therefore, this manufacturing asymmetric test variants. process is suitable for small prototype test series. Furthermore, for each of the three test gear geometries produced Especially when focusing on the tooth root bending strength using the manufacturing process “grinding into solid material,” a where manufacturing deviations in the tooth root geometry can comparison was carried out between three of the test gears produced lead to a misinterpretation of the bending strength of the designed

August 2020 35 geometry, a high contour accuracy is necessary. 10300-3. The relatively high production times per test gear compared to [ 12 ] Kapelevich, A., 2000, “Geometry and design of involute spur gears with gear hobbing can, however, be compensated by the elimination of asymmetric teeth,” Mechanism and Machine Theory, 35(1), pp.117–130. long design and procurement times for special production tools as well as the costs of such tools. [ 13 ] Kapelevich, A. and Shekhtman, Y., 2009, “Tooth Fillet Profile Optimizations Therefore, the results of this paper show a suitable method for for Gears with Symmetric and Asymmetric Teeth,” Gear Technology, 26(7), pp.73–79. the fast, precise and cost-efficient production of special gears for prototype tests. [ 14 ] König, J., Koller, P., Tobie, T., and Stahl, K., 2015, “Correlation of Relevant Furthermore, due to the acquisition of a 5-axis machining center Case Properties and the Flank Load Carrying Capacity of Case-Hardened at the research institute in the meantime, a direct comparison can Gears,” ASME 2015 International Design engineering Technical Conferences also be made with regard to machining time and production costs & Computers and Information in Engineering Conference, ASME, Boston (MA). for gears of identical geometry in future research work. [ 15 ] Kratzer, D., Dobler, F., Tobie, T., Hoja, T., Steinbacher, M., and Stahl, ACKNOWLEDGMENTS K., 2019, “Effects of low- temperature treatments on surface hardness, The authors thank Liebherr-Verzahntechnik GmbH for their support. retained austenite content, residual stress condition and the resulting tooth root bending strength of case-hardened 18CrNiMo7-6 gears,” Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical BIBLIOGRAPHY Engineering Science, 64. [ 1 ] Bouquet, J., Hensgen, L., Klink, A., Jacobs, T., Klocke, F., and Lauwers, B., 2014, “Fast Production of Gear Prototypes – A Comparison of Technologies,” [ 16 ] Langheinrich, A., 2014, “Geometrie, Beanspruchung und Verformung asym- Procedia CIRP, 14, pp.77–82. metrischer Stirnradverzahnungen,” Dissertation, FZG, TU München.

[ 2 ] Brown, F. W., Davidson, S. R., Hanes, D. B., and Weires, D. J. and Kapelevich, [ 17 ] Langheinrich, A., Otto, M., and Stahl, K., 2015, “Geometry, strain and A., 2010, “Analysis and Testing of Gears with Asymmetric Involute Tooth deformation of asymmetric spur gears,” International Conference on Gears. Form and Optimized Fillet Form for Potential Application in Helicopter Main VDI-Berichte 2255, Garching, pp.273–281. Drives,” Proceedings of the AGMA 2010 Fall Technical Meeting, AGMA, Milwaukee (WI), pp.46–55. [ 18 ] Neipp, C., Weber, C., Surm, H., Bleck, W., Tobie, T., Stahl, K., and Zoch, H.-W., 2017, “Development of New Steels for Lightweight Construction,” [ 3 ] Deng, G., Nakanishi, T. and Inoue, K., 2003, “Bending Load Capacity Proceedings of the 5th International Conference on Steels in Cars and Enhancement Using an Asymmetric Tooth Profile,” JSME International Trucks, SCT, Amsterdam. Journal Series C, 46(3), pp.1171–1177. [ 19 ] Nigade, R. V. and Wink, C. H., 2018, “Impact of root geometry manu- [ 4 ] Dobler, F., Tobie, T., and Stahl, K., 2015, “Influence of Low Temperatures facturing deviations from a theoretical hob rack on gear bending stress,” on Material Properties and Tooth Root Bending Strength of Case-Hardened Proceedings of the AGMA 2018 Fall Technical Meeting, AGMA, Chicago (Il). Gears,” Volume 10: ASME 2015 Power Transmission and Gearing Conference; 23rd Reliability, Stress Analysis, and Failure Prevention [ 20 ] Paucker, T., Otto, M., and Stahl, K., 2019, “A precise prediction of the tooth Conference, Boston (MA). root stresses for involute external gears with any fillet geometry under consideration of the exact meshing condition,” Proceedings of the Institution of [ 5 ] Dobler, F., Tobie, T., Stahl, K., Nadolski, D., Steinbacher, M., and Hoffman, Mechanical Engineers, Part C: Journal of Mechanical Engineering Science. F., 2016, “Influence of hardening pattern, base material and residual stress condition on the tooth root bending strength of induction hardened gears,” [ 21 ] Pedersen, N. L., 2010, “Improving bending stress in spur gears using asym- Power Engineering, Chongqing, China, pp.287–294. metric gears and shape optimization,” Mechanism and Machine Theory, 45(11), pp.1707–1720. [ 6 ] Frühe, T., 2010, “Berechnung und Minimierung der Zahnfußspannung von Standard- und LowLos-Verzahnungen,” Dissertation, FZG, TU München. [ 22 ] Roth, Z. and Opferkuch, J., “High load capacity gear root fillet contour with a bézier curve,” International Conference on Gears, pp.719–732. [ 7 ] Güntner, C., Tobie, T., and Stahl, K., 2017, “Alternative microstructures and their influence on mechanical properties of case-hardened gears,” [ 23 ] Stahl, K., Höhn, B.-R., and Otto, M. and Fröh, A., 2012, “Standard calcula- Forschung im Ingenieurwesen, 81(2-3), pp.245– 251. tion of the geometry and load capacity of asymmetric involute tooth systems. [Normberechnung der Geometrie und Tragfähigkeit von asymmetrischen [ 8 ] Güntner, C., Tobie, T., and Stahl, K., 2017, “Influences of the residual Evolventenverzahnungen],” Konstruktion, 10 (2012). stress condition on the load carrying capacity of case hardened gears,” Proceedings of the AGMA 2017 Fall Technical Meeting, AGMA, Columbus [ 24 ] Weber, C., Tobie, T., and Stahl, K., 2016, “Investigation on the tooth (OH), pp.328–344. root bending strength of gears with special involute tooth shape,” Power Engineering, Chongqing, China, pp.303–310. [ 9 ] Hyatt, G., Bylund, N. and Chaphalkar, N., 2014, “Analysis of Gear Root Forms: A Review of Designs, Standards and Manufacturing Methods for Root [ 25 ] Wickborn, C., Tobie, T., Höhn, B.-R., and Stahl, K., 2015, “HiPerComp: Forms in Cylindrical Gears,” Gear Solutions Magazine (2014), pp.48–56. High performance materials for gears,” International Conference on Gears. VDI-Berichte 2255, Garching, pp.985– 995. [ 10 ] International Organization for Standardization, 2006, “Calculation of load capacity of spur and helical gears - Part 3: Calculation of tooth bending [ 26 ] Winkler, K. J., Schurer, S., Tobie, T., and Stahl, K., 2019, “Investigations strength,” ISO 6336-3. on the tooth root bending strength and the fatigue fracture characteristics of case-carburized and shot-peened gears of different sizes,” Proceedings [ 11 ] International Organization for Standardization, 2014, “Calculation of load of the Institution of Mechanical Engineers, Part C: Journal of Mechanical capacity of bevel gears — Part 3: Calculation of tooth root strength,” ISO Engineering Science.

ABOUT THE AUTHORS

Christian Weber, M.Sc., Dr.- Ing. Thomas Tobie, and Prof. Dr.- Ing. Karsten Stahl are with the Gear Research Centre (FZG), Technical University of Munich.

36 gearsolutions.com EXPAND YOUR REACH

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

To learn more, contact national sales manager Dave Gomez at [email protected] or call 800.366.2185 ext. 207

August 2020 37 OPTIMIZATION OF RACK AND PINION FOR OFFSHORE JACK-UP APPLICATIONS

Printed with permission of the copyright holder, the American Gear Manufacturers Association, 1001 N. Fairfax Street, Suite 500, Alexandria, Virginia 22314. Statements presented in this paper are those of the authors and may not represent the position or opinion of the American Gear Manufacturers Association. (AGMA) This paper was presented September 2018 at the AGMA Fall Technical Meeting in Oakbrook, Illinois. 18FTM03

46 gearsolutions.com Gear design has multiple parameters from which the gear designer can choose – while some are beneficial, some can negatively affect the system; therefore, a structured approach needs to be taken in order to define a custom pinion and rack for a liftboat.

By ADRIAN NOWOISKY

iftboats or jack-up oil rigs are essential for the Increased life expectation. oil and gas industry. The subsystem (rack, pin- Reduction in root bending stress and contact ion, gearbox, and brake) within the system lift stress. boat has specific requirements that need to be Reduced cost. L customized appropriately. This paper shall outline the Increase power density. design process of a rack-and-pinion system and show Weight reduction. how the design can be optimized. To start a design, the loads at the pinion need to be The nature of gear design is that it has multiple known. The naval architect can provide the weight parameters from which the gear designer can choose. of the legs and the hull to get the pinion basic lay- While some are beneficial, some can negatively affect out. In the next sections, this paper will discuss how the system. Therefore, a structured approach needs to parameters such as profile shift, diametral pitch, pres- be taken in order to define a custom pinion and rack sure angle, and number of teeth will affect the con- for a liftboat. The influence of major gear parameters, tact stress and what strong design characteristics are such as modul, profile shift coefficient, as well as the influenced by these. All parameters discussed in the pressure angle, will be analyzed, and their impact on next section are defined and calculated per standard the design discussed. Based on the previous discussion, calculation [2, 3]. a gear design will be selected and analyzed. As a next step in the design process, the optimization phase will 1.1 INFLUENCE OF MODULE (DIAMETRAL PITCH) show how to reduce the contact stress in the system, as The diametral pitch (module), in combination with well as change from an involute profile into a multi- the number of teeth, are the most important basic radii pinion design. Both pinion designs will be com- parameter in gear design, as shown in section 1.4, pared and validated with FEA (finite element analyses) Figure 4, the correlation between module, pitch calculation to show and validate the improvement. diameter, and gearbox output torque. The weight of The final design will not only extend the life of the hull and legs are given by the naval architect and product, it will save the customer a great deal of time translating into the pinion load in metric tons. The and financial resources, as it will last longer in service. pinion load is held constant, a higher module (smaller This paper can be used as a guideline and starting diametral pitch) is selected, and the gearbox output point to design a rack and pinion for offshore jacking torque will increase. applications. Vice versa, a smaller module (higher diametral pitch) gearbox torque will decrease. With a higher 1 INTRODUCTION RACK AND PINION module (smaller diametral pitch), these general con- DESIGN clusions apply: Offshore liftboat applications are used, and their spe- Increased root bending strength. cifics are long- known in the oil and gas industry. The Reduced contact stress. typical operation modes, as well as the details for the Increase of pitch diameter (pinion size). materials used for the rack and pinion, are explained Increased rack width and cost. in detail for these applications [1]. This paper will Typically, it is intended to keep the gearbox torques pay attention to the design of the pinion and show low, to reduce weight and cost in the system. Therefore, potential to optimize the system and increase the life the selection of the diametral pitch (module) will in regard to contact stress. In these applications, the determine the gearbox output torque significantly. To main focus pays attention to maintaining sufficient define the diametral pitch (module), it is important margin for root-bending stress. to meet the root-bending stress requirements for this For all designs shown herein, the assumption can rack and pinion. Doing so will establish the baseline be made that this condition is met. The nature of gear for this design. If the system is designed too conser- design is that the gear engineer has multiple param- vatively, the cost and weight will increase drastically eters that influence each other and improve the design and will affect the sizing of the rack, pinion, gearbox, toward: brake, and motor.

August 2020 39 1.2 INFLUENCE OF PROFILE SHIFT COEFFICIENT The profile shift applied to the pinion will be adjusted in the rack through the calculated center distance, as well as the length (or factor) of the dedendum and addendum definition. While modifying the profile of the pinion positive, the designer needs to keep the minimum tooth thickness at the outside diameter in mind. That sets the limit to the maximum applicable profile shift coefficient at the pinion. If the profile is shifted positively on the pinion, the following conclusions can be taken: Smaller tooth thickness at top (sharp tooth tip). Increased contact ratio. Extension of center distance. Reduction in contact stress. In Figure 1, we see the gear profile changing as specified with the profile shift factor. Table 1 points out that the root form diameter is not linear, growing as the outside diameter increases as well as the tooth thickness decreases with a higher positive profile shift Figure 1: Pinion comparison in profile shift. modification. The designer shall keep in mind that the same characteristics seen on the pinion will apply to the rack. The literature Profile dNF da san [3, 4] recommends maintaining the minimum tooth thickness at the shift outside diameter according to Equation 1. [1] [inch] [mm] [inch] [mm] [inch] [mm] Equation 1 0.15 18.181 461.79 26.850 682.00 1.181 30.000 where 0.25 18.301 464.85 27.448 697.20 0.984 25.000 san is normal tooth thickness at tip circle. m is module. 0.35 18.500 469.90 28.047 712.40 0.795 20.200 The major concern is that the small contact ratio in the rack and 0.40 18.624 473.05 28.346 720.00 0.669 17.000 pinion design will lead to high plastic deformation at the rack tip. It also can be taken into consideration that a smaller profile modi- Table 1: dNF active root diameter. fication can account for more plastic deformation on the pinion, and it allows for adjusting the center distance accordingly during a scheduled maintenance after five or 10 years of service. In practice, after significant hours of service, it is often seen that tooth tips are as sharp as “razor blades,” which will lead to an immediate replacement of the pinion. Since the racks are made out softer material, they will wear into a much more optimal shape during operation, rack teeth are seen to be deformed with two significant concave deformations over the line of action.

1.3 INFLUENCE OF PRESSURE ANGLE a In the industry and on all kinds of applications, higher pressure angles are widely discussed [5, 6] and used. For this specific application, a higher pressure angle is common to achieve higher root- bending strength and reduced contact stress. For the purpose of evaluating the impact on contact stress for a given load, pressure angles of 25˚, 28˚, 30˚, and 32˚ are investigated while maintaining the same profile shift, as well as diametral pitch. According to involute generation theory, a gear profile is covering pressure angles from 0˚ to 60˚. It is the authors understanding that for this specific application, the definition of the base diameter db is more important in the Figure 2: Generation of the involute function. initial design phase, when the pressure angle is part of Equation 2. As pointed out, it is preferred to have a small pinion pitch diameter generates a smaller-base diameter and vice-versa. A smaller pres- within the system to reduce the output torque at the gearbox in the sure angle generates a bigger base diameter. Typically with higher- system. (Figure 2) pressure angles the following characteristics are benefiting rack and pinion: Equation 2 Reduction in root bending stress. where Reduction in contact stress. a is the pressure angle. Reduction in contact ratio. m is the module. Higher radial loads. z is the number of teeth. As shown in Figure 3, below the reduction in root-bending and As shown in Equation 2, the impact of a higher-pressure angle contact stress is slowing at a pressure angle of 28 degrees. Therefore

gearsolutions.com Figure 5: Involute Pinion design.

Figure 3: Root bending and contact stress depending on pressure angle.

Figure 6: Involute Rack design.

gearbox output torque and therefore will influence the system in size and cost. Figure 4 shows the linear relation of pitch diameter, number of teeth on the pinion, and gearbox torque needed to operate at a constant pinion load. As illustrated, the pinion torque for a 7-tooth pinion starts ≈ 121,697 ft-lbs (165 kNm) and increases for a 9-tooth pinion up to 165,951 ft-lbs (225 kNm). In the liftboat fleet, there are rack and pinions known with more than 10 teeth. Typically at a given load and module, a higher number of teeth at the pinion reduces bending — and contact — stress significantly. This enhanced life for pinions Figure 4: Required Gearbox output torque. with more than 8 teeth can be explained with a much longer radius of curvature as well as associated a better contact ratio compared to a Description Symbol Unit Pinion Rack 7-tooth pinion. The trade-off for that extended pinion life is a heavier jack-up gearbox and pinion. In the industry, pinions made with 7 or 8 Material - - 4340H ASTM A514 Grade Q teeth are the most common. The downside of a low number of teeth for the pinion is the increased number of load cycles. For example, a Normal module m mm 76 pinion with 8 teeth would need 12.5 percent fewer revolutions, and a

Normal pressure angle an DEG 28 9-tooth pinion would need 22.2 percent fewer revolutions compared to a 7-tooth pinion to achieve the same travel distance on the rack. Helix angle b DEG 0 n On the contrary, let’s say a 10-tooth pinion will be able to last longer, Number of teeth z 1 7 1184 and the plastic deformation is less significant, compared to a 7-tooth (90m rack) pinion, assuming the same amount of service hours. It would also Profile shift coefficient x 1 0.4 - be possible to adjust the center distance after an x amount of service to accommodate the plastic deformation on the pinion. It can be Face width b mm 177.8 152.4 concluded in this discussion that it is rather a decision within the

Tip diameter da m m 720 325 system on the number of teeth the pinion should have. Pitch diameter d mm 532 ∞ 1.5 RACK AND PINION GEOMETRY Root form diameter dNf m m 473.46 160 Based on the discussion in sections 1.1 to 1.4, the following gear design has been chosen for the pinion and rack. Due to the manu- Base diameter db m m 469.728 - facturing process and this specific application, the rack and pinion Contact ratio ea 1 1.153 need to account for sufficient backlash and tip clearance. Table 2

Backlash jt m m 8,37 – 4.776 and Figures 5 and 6 illustrate the chosen gear geometry. In the next step, this rack and pinion system will be analytically evaluated and Table 2: Specified rack and pinion design. further optimization potential discovered. it can be concluded that higher-pressure angles above 30˚ tend to 2 ANALYTICAL EVALUATION AND OPTIMIZATION have more technical disadvantages than the gain in root bending- The basic hertzian stress calculation according to gear standard cal- strength, as well as pitting resistance. culations [7, 8] is done based on the geometry and materials given. As typical for these applications, the calculation will be separated 1.4 INFLUENCE OF NUMBER OF TEETH AT THE PINION between static loads as well as combined loads, according to certifica- As broadly explained, the rack and pinion design will determine the tion body requirements [9].

August 2020 41 2.1 ISO 6336 VS. AGMA 2001-D04 CONTACT STRESS ASSESSMENT Operation Pinion Load Gearbox output Pinion contact stress torque σH – per sc – per As expected, the high-loaded tooth flank ISO 6336 AGMA 2001-D04 results in high contact stress. Based on these results and a service life of more Unit [Short [Metric [In-lbs] [kNm] [ksi] [N/mm2] [ksi] [N/mm2] than 20 years, the life expectation per gear ton] ton] calculation is zero due to exceeding the Leg Operation 71.7 65 1,501,218 170 235 1,620 244 1,684 permissible contact stress. (Table 3) Hull Operation 187.4 170 3,926,263 587 380 2,620 395 2,723 2.2 HERTZIAN CONTACT THEORY Preload Operation 248 225 5,196,525 587 437 3,014 454 3,133 Based on the hertzian contact theory [10], Max. Normal Holding 264.6 240 5,542,960 626 451 3,113 469 3,236 the rack-and-pinion contact stress can be analyzed in more detail. In order to take a Severe Storm Holding 347.2 315 7,275,135 822 517 3,566 538 3,707 deeper look into the involute profile of the Test load 396.8 360 8,314,440 939 553 3,812 575 3,963 pinion, an approximation of the radius in the dedendum must be taken and used. As Table 3: Pinion load – contact stress. shown in Figure 7, the radius is starting at the SAP (dNf) and will meet the involute profile tangentially approximately at the pitch diameter d. This model is an analog to a cylinder in contact with a flat surface. This method enables the designer to explore stress-reduction potentials, as well as analyzes the principle stress in each direction of this system. Figure 8 shows the comparison between an involute profile pinion and a multi-radii pinion. For the load case “preload jacking,” the nominal contact stress s is with the involute profile c Figure 7: Involute Pinion design analogue to cylinder on flat surface. design 396 ksi (2,732 N/mm2). It is intended to increase the dedendum radii up to 4.13 inches (105 mm) while the nominal contact stress drops to 347 ksi (2,395 N/mm2). In the daily business of gearbox manufacturing, we use the same principle when the bearing life is not met. The first typical iteration of the bearing supplier is to increase the number of rollers or to increase the roller diameter. Equations 3 to 5 as mentioned in [10] illustrate how the contact stress is calculated. Based on Equation 4, changes in rPinion are most sensitive to the result of the contact width a of the cylinder in contact. In a system where loads are given and face width is determined by the steel plate, rPinion is the variable with the most leverage to reduce the contact stress.

Equation 3

Equation 4

Equation 5 where E is modulus of elasticity. L is length of cylinder. a is 1/2 of the contact width. F is Force. rPinion is radius of the dedendum.

2.3 PINION DETAIL DESIGN As discussed in the previous section, the pinion design will have an increased dedendum radius, compared to the approximation of the involute profile. In theory, this will reduce the nominal contact stress by 10 percent or more depending on the pinion design and tooth form. Subsequently, the involute form will be replaced by 3 different radii, plus tip- and root- radius. All curvatures will mate Figure 8: Involute profile vs. multi radii contact stress.

42 gearsolutions.com Overall, it can be concluded that a custom pinion design will reduce the contact stress drastically and extend the expected life of the system. Figure 9: Optimized radii pinion design.

is important for the life of the rack and pinion that the pinion is well aligned relative to the rack to maintain the predicted contact stress. As typical in the shipbuilding industry and a marine environment, the precision is limited to the capability of handling big machinery pieces and welding tolerances. Therefore the legs are typically guided as shown in Figure 10 [12]. The guides are adjusted during installation and custom fit for each leg. It is important to monitor the wear of the guide plates as well as the rack deformation and backlash between rack and pinion. The backlash shall be defined with sufficient tolerance with respect to the system tolerance. The maximum backlash tolerance shall be defined to maintain a minimum contact ratio of ea = 1.015. It also needs to be mentioned that the whole jacking tower strains within the elastic limits of the material during jacking operation. This enables the rack to move relative to the pinion until an equilibrium of pinion forces is in place within the tower structure. All these aspects need to be taken into consideration for the pinion designer and the naval architect. 3 NUMERICAL EVALUATION Linear FEA analyses were carried out using ANSYS R19.0 to analyze the stress of each pinion design. The rack and pinion was modeled so the contact of rack and pinion is in the lowest point of single tooth contact (equal to point B per DIN and ISO) of the pinion. The mesh was discretized in the area of contact to achieve the most accurate results. The load cases leg operation, pre-load operation and maximum storm Figure 10: General arrangement leg guides. hold were used to analyze and compare both designs and results.

FEA Radii Cylinder in FEA Involute Contact stress 3.1 LINEAR FEA AT STORM HOLDING COMPARISON INVOLUTE VS. RADII pinion design contact (r = pinion design per AGMA PINION ksi [N/mm2] 105mm) ksi [N/mm2] 2001-D04 sc ksi [N/mm2] ksi [N/mm2] The results of the FEA contact stress is showing typically 5 percent to 10 percent Leg Operation 165 [1,135] 184 [1,266] 188 [1,296] 244 [1,684] lower than calculated stress based on Preload Operation 315 [2,177] 341 [2,353] 357 [2,459] 454 [3,133] hertzian contact theory. Comparing the results with AGMA/ISO contact stress Max. Storm Holding 380 [2,616] 404 [2,784] 414 [2,855] 538 [3,707] calculation, the difference is typically 18 percent to 23 percent lower. Figures 11 and Table 4: Contact stress comparison. 12 illustrate the results for the load case of preload jacking for both pinion designs. tangentially with each other. Figure 9 shows the transformed and The FEA results agree with the analytical approach of modify- stress-optimized pinion design. The involute pinion design will ing the involute pinion design to a multi radii design. Furthermore, only be used as a theoretical step to get to the multi radii design, we have reduced the pinion stress by approximately 11 percent of where the pitch diameter is only a theoretical reference from the what will increase the pinion and rack life. It also confirms that a involute profile. custom design for rack and pinion is essential for these applications. The naval architect can now find a good compromise between rack 2.4 SYSTEM INFLUENCE widths and pitch diameter to keep the cost for the jacking system This article will also cover the system aspect of pinion and rack. It as low as possible.

August 2020 43 Figure 11: Radii pinion FEA results on rack. Figure 12: Involute pinion FEA results on rack.

4 CONCLUSION BIBLIOGRAPHY Table 4 summarizes all results of each pinion design and calculation [ 1 ] Nowoisky, Adrian, 2017 “Predicting Life on Through Hardened Steel Rack method. It can be concluded that the contact stress calculation per and Pinion for Jacking Applications in the Offshore Industry,” AGMA FTM17, Dana Incorporated, p. 2-3. AGMA and ISO, with their allowable stress sac/sHP are not fully applicable to this specific application. However, the contact stress [ 2 ] DIN 3960: 1987, Definitions, parameters and equations for involute cylin- needs to be carefully evaluated and analyzed. The difference between drical gear pairs. the FEA results of the involute profile and the standard calculation [ 3 ] AGMA 913 – A98: 1998, Method for specifying the geometry of spur and method is not accurate enough (20% - 23%) difference. This may lead helical gears. to an overly cautious design with higher cost and weight. On the other hand, the difference between the hertzian contact theory and [ 4 ] Matek, Wilhelm., 2001, Roloff/ Matek Maschinen- elemente, edition 15, FEA results of the involute pinion is 5 percent — 3 percent close VIEWEG Verlag, Page 673, Chap. 21.1.4 - 3. enough. Interestingly, the FEA results from the radii design are [ 5 ] Dr. Fuentes-Aznar, Alfonso, 2017 “Gear Tooth Strength Analysys of High much farther apart to the results of the hertzian contact theory Preassure Angle Cylindrical Gears,” AGMA FTM17, Rochester Institute of (12.5% - 8.5%). Overall, it can be concluded that a custom pinion Technology, p. 2. design will reduce the contact stress drastically and extend the [ 6 ] Miller, Rick, 2016 “Designing Very Strong Gear Teeth by Means of High expected life of the system. Pressure Angles,” AGMA FTM16, Innovative Drive Solutions LLC, p. 2. Under the first operational loads, the rack and pinion will plasti- [ 7 ] ANSI/AGMA 2101-D04, Fundamental Rating Factors and Calculation cally deform. It is the author’s understanding that residual stresses Methods for Involute Spur and Helical Gear Teeth (Metric Edition). will be induced during that run-in period in the material and pre- vent further deformation while elastic. This phenomenon is called [ 8 ] ISO 6336-2:2006, Calculation of load capacity of spur and helical gears elastic shakedown [11] or strain hardening. It is widely used in pres- – Part 2: Calculation of surface durability (pitting) + Corrigendum ISO 6336- 2/AC1:2008. sure vessel analyses and evaluation. Since all inf luences are not fully understood, it is recommended to monitor the deformation of rack [ 9 ] ABS Mobile Offshore Drilling Units 2016, Part 6-Chapter 1 -Section 9 and pinion in regular intervals. Reasonable means could be backlash “Jacking and Associated Systems,” p. 79. or pinion tip clearance to the rack. A specified gauge could deter- [ 10 ] Ansel C. Ugural, Saul K. Fenster; “Advanced Mechanics of materials and mine the acceptance criteria, and the service could be performed applied elasticity,” Fifth edition, p.163. in a timely manner. It is up to the liftboat operator and government [ 11 ] Williams, John A.; “Contact between solid surfaces”; 2001, p. 36. requirements as to what kind of measures are taken to maintain safe and sound jacking operation during the life of a liftboat. [ 12 ] Picture courtesy of Allriggroup.

ABOUT THE AUTHORS

Adrian Nowoisky is a senior product engineer at Dana Incorporated specializing in designing custom gearboxes for industrial applications. He earned a Dipl. Ing. (FH) degree from the Anhalt University of Applied Sciences in Koethen/ Germany in 2005. In his professional experience of more than 15 years, Nowoisky took part of developing a dual clutch transmission at ZF Getriebe GmbH, accessory gearboxes for jet engines at Rolls-Royce, as well as jack up and industrial gearboxes. At the ThyssenKrupp Marine Systems shipyard in Kiel/ Germany, he gained experience designing machinery for submarines.

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

Get your FREE subscription, plus our online content, at www.gearsolutions.com August 2020 53 COMPANY SMT PROFILE

SERVING ALL SECTORS OF THE TRANSMISSION AND DRIVELINE DEVELOPMENT INDUSTRY

54 gearsolutions.com SMT is a globally integrated leader in mechanical transmission engineering services and software development with a collective of experienced and passionate experts who deliver services and technologies trusted by the world’s leading transmission and driveline engineers.

By KENNETH CARTER, Gear Solutions editor

hile gear design can be a challenging endeav- solving the difficult problems that customers face, or, the results justify the complexity of the providing expertise and knowhow,” said Dr. Paul task. However, the process can be made a lot Langlois, software engineering director at SMT. “Our W easier with the right tools. expertise in areas such as NVH, efficiency, and shift The software and engineering experts at Smart quality, with proven ability to solve problems within Manufacturing Technology (SMT) have created solu- these difficult areas, distinguish us. SMT aim to solve tions that can assist and eliminate many design steps, high difficulty problems that others cannot solve, allowing for a quicker process and more robust final rather than providing a pool of resources for routine design. SMT’S MASTA SOFTWARE SMT’s flagship CAE software, MASTA, is well known as the premier specialized transmission and driveline design and analysis tool. MASTA enables engineers to design robust, efficient, lightweight, and quiet transmissions from concept design, through detailed design, and all the way to manufacture, enabling true design for manufacture. MASTA is complemented by SMT’s MEASA TE and NVH hardware and software solution, which allows easy and MASTA - LTCA 3D View. (Courtesy: SMT) accurate data acquisition of TE and NVH test data, together with data analysis tools developed work when customers are short of them. This combina- specifically for transmission applications. tion of world leading software, high-class project engi- There are considerable productivity benefits from neers, and a proven record of problem-solving resolu- having a single workflow only requiring input of data tions encapsulates SMT’s expertise-based approach.” once resulting in fewer opportunities for introducing errors. SMT’s MASTA software enables engineers to IN BUSINESS SINCE 2002 start the process from a clean sheet, build models SMT started life as a company in 2002 with a group quickly, analyze their models and optimize their of engineers who were experts in software, system designs using accurate results for maximum efficien- dynamics, gears, and bearings, and who are still with cy and accuracy when working on a project, accord- the company today. SMT was founded with a clear ing to Pramod Mooneeramsing, director of sales and vision to provide solutions to engineers to bridge the marketing at SMT. gap between design and manufacturing, according to “We provide the complete suite to help engineers Mooneeramsing. get the right results at any stage of their design pro- From its beginnings, SMT sought to make use of cess, before it gets to the manufacturing process,” he modern technologies. said. “Saving time and cost, providing accurate analy- “With a strong architecture built in from the start sis results, and enabling to build designs optimized for this enables our software to be robust and easily exten- manufacture are just a few of the many advantages.” sible,” Langlois said. SMT is a Microsoft Gold partner and develops its SMT’S ENGINEERING SERVICES software on the latest Microsoft platform. This allows “SMT’s engineering services team are dedicated to rapid inclusion and integration of new features with

August 2020 47 no legacy code or platform constraints to hold back further develop- level, according to Langlois. ment, according to Mooneeramsing. “Scripting allows the users to interact with MASTA models and “Software should enable engineers to optimize the use of their analyses from their own code, written in .NET languages such as C# time in making important engineering decisions and allow them to or languages that engineers are often familiar with already such as spend less time on manual, time consuming tasks,” he said. “With Python or MATLAB,” he said. “Users can therefore write code in the MASTA, the modern and intuitive interface is designed to ensure languages they are used to while taking full advantage of the devel- that, when working with the software, it is user friendly and stream- opment tools and libraries which are available for them.” lined. Another important and common goal for SMT is ensuring that There is a continual large focus on automation within many indus- all types of engineers at different levels of knowledge can use the tries. Automation enables lean design and development workflows software, whether they are an expert or not.” to be optimized while minimizing the potential for errors. MASTA’s scripting function enables MASTA to be easily integrated into such ‘MASTA, BUILT FOR YOU’ workflows and even enables MASTA to be used as the platform on A focus on software quality since the start of the business, together which such workflows are built, according to Mooneeramsing. This with a continual focus on stability throughout the development is also an important feature for companies that need to protect their process from expert developers, has enabled SMT to be very flex- intellectual property but need a deeper integration with MASTA. ible toward bespoke requirements for the end user, according to Mooneeramsing. GROWING WITH THE EV MARKET “SMT work with users of the software to ensure the features meet SMT is always looking for ways to better itself and the software prod- their requirements for now and the future,” he said. ucts and features it produces, and with the gear market in the auto- One of the key distinguishers of the software is that the modu- motive industry moving toward electric vehicles, SMT is confident lar construction allows customers to choose the modules they need it will continue to excel in providing solutions in full system design for their requirements and not pay for functionality that they are and analysis within MASTA, according to Mooneeramsing. “What I mean by full system analysis is a complete, high fidelity model of a transmission, including the electric motor, where the assumptions in the system are kept to an abso- lute minimum,” he said. “Not only should it be very accurate, it should also be easy, not a struggle to get the tool to do what you want. We have testing facilities in the U.K. where we test EV cars. We achieve results that correlate with MASTA to give our engineers tremen- dous confidence in our technology.” With all of SMT’s innovations and world- wide expansion, it only serves to demonstrate how the company will continue to focus on growth, according to Mooneeramsing. “We opened an office in South Korea last year and it’s been very well received, generating lots of interest,” he said. “We’ve had our U.S. office readily established as well, MASTA For EV Model. (Courtesy: SMT) meaning we’re always trying to make sure we work closer with our customers at a local not going to use, according to Mooneeramsing. Using the right tools level. Having offices across the globe allows us to work closely with within the software, in this manner, reduces cost while maximizing a wider range of customers, giving us added insight into a variety productivity. of challenges. Whether it’s software related or engineering-services “In many CAE tools, unnecessary additional costs are common related, we are always working with customers to make sure we are when wishing to take advantage of available computing power,” he providing the best of the best.” said. “With MASTA, you get the whole package. SMT software can take full advantage of the processing power available via multi-core ‘CUSTOMER AND QUALITY ARE THE PRIORITY’ processors. Further, Microsoft’s decision to support platforms other SMT’s relationship with its customers is a key driver in the constant than Windows further increases this advantage, with new develop- innovation behind the MASTA suite. The feedback process and devel- ments allowing SMT to leverage the power of High-Performance opment plan are important in acknowledging the customer needs Computing (HPC) running on Linux.” first and foremost, according to Mooneeramsing. Continuing the company ethos of building the software around “If a customer wants a specific feature in MASTA, SMT facilitates customer requirements, with an open and liberal approach, is what that as the driving force to ensure customers are using the right tools continues to drive SMT’s innovation. for their projects,” he said. “This opens the door for many users to see for themselves the benefits of the whole suite, learning new features SCRIPTING they may have been limited from in other software packages.” One huge addition for SMT in the past year has been the release of The company now has more than 100 employees, with a large their new scripting functionality in MASTA 10; a product innovation number of SMT staff with PhDs in their areas of expertise, accord- that enables MASTA users to work with the software at a whole new ing to Langlois.

48 gearsolutions.com The SMT testing facility. (Courtesy: SMT)

“As a customer-focused company, we aim to have staff at all levels, support queries and further help; it’s not just reactive,” he said. “The no matter what role, to understand that the customer and quality Support Portal gives access to, for example, a wide range of videos, are the priority and that anything they do they should keep that in which have proved very popular with SMT’s customers as a method mind,” he said. of training and also a method of answering customer support queries “The software itself, I would say in a nutshell, is about 90 percent on certain functions and workflows.” driven by our customers,” Mooneeramsing said. This focus on the customer is reflected in the excellent feedback SMT has received regarding its customer support, according to CUSTOMER-FIRST ETHOS Mooneeramsing. With a 96 percent overall satisfaction rating and a The experts at SMT believe that providing great customer support Net Promotor score of 55, a value for this standard metric, which is is crucial to their mission. They are passionate about helping their deemed excellent, it is clear that SMT’s customers are happy. With customers achieve their objectives efficiently, according to Dr. Rob a global reach and local support, if customers need to talk to one of Forrest, customer support manager. SMT’s support engineers, or help with something much more com- “SMT is committed to delivering first-class support to all our plex, SMT is ready. customers as part of a company-wide ‘customer-first’ ethos, and we always endeavor to work closely with them to ensure both ongoing OEM CUSTOMERS ALL OVER THE WORLD success and satisfaction,” he said. Within 18 years of being in business, with four major OEMs in According to Mooneeramsing, SMT engineers are some of the best Germany, as well as OEMs and Tier 1 suppliers in countries such as in the industry. the U.S., Japan, Korea, and China, trusting the company’s software “If needed, we give you direct access to them, and that’s all part and being longstanding customers is a huge achievement for SMT, of the customer-first ethos in our philosophy, to make sure you get according to Mooneeramsing. the highest level of customer support, whether you’ve got a small “I’ve had a very personal relationship with each and every com- problem and you just need to talk to one of our support engineers, pany,” he said. “This is why our philosophy is consistent in every or you need help with something much more complex,” he said. market. Wherever we do business, I make sure everyone interacting “We’re open. We’re there for everybody, and that’s really important with a customer focus on that customer’s technical and commercial for us.” needs. We’re always happy to sit down and discuss anything with a Communication is key at SMT; internally, all departments work customer. We are very much a technology-minded business thinking together to one common goal, the customer comes first, according of how we can help the customer.” to Mooneeramsing. “This high level of integration ensures the customer support received is also very open, the Portal that they use is of high techni- www.smartmt.com cal caliber, and resources are readily available to open the door to MORE INFO

August 2020 49 PRODUCT SHOWCASE NEW PRODUCTS, TRENDS, SERVICES & DEVELOPMENTS

integral geared motors combine Bodine’s high-performance type 33A7 permanent magnet DC motor with two new hypoid gearheads. They are the ideal drive solution for applications that require compact size, quiet operation, high torque-density, and low-energy consumption. Typical applications include conveyors, pumps, packaging, industrial automation, and wide range of solar- or battery-powered equipment. More efficient than comparable worm- gear models, Bodine’s new hypoid gearmotors can deliver up to 1,535 lb-in (173 Nm) torque while using 40-60 percent less energy than a same-size worm gearmotor. Side-by-side tests have shown that hypoid gearmotors can run as much as 15 percent cooler than worm-gear gearboxes, resulting Hainbuch’s two- and three-jaw model adaptation to clamp cubic parts is the small alternative to the large in lower power consumption and longer centric vice. (Courtesy: Hainbuch) lubricant life. These hypoid gearmotors can deliver the same torque with a smaller, The two-jaw module can handle turn- more efficient motor compared to worm- Hainbuch offers addition ing applications up to 1,500 RPM. Due to its gear boxes, resulting in a smaller mount- compact profile, it is a great alternative to ing footprint, and the hollow-shaft design to modular family large and heavy centric vises. The two-jaw eliminates expensive shaft couplings and with two-jaw module and three-jaw module use the Hainbuch col- mounting hardware. Hardened steel gears let chuck as their base. Change-over is pos- insure long-life and maximum performance. With a wide range of part diameters, con- sible without removing the collet chuck and The initial product launch includes 60 figurations, and small quantities, the dream realignment thanks to Hainbuch’s Centrex standard models with gear ratios from 5:1 setup would be to have maximum flexibil- quick-change interface. to 240:1. Thirty-five standard models are ity. Hainbuch’s modular system allows that. Hainbuch’s modular solution, consist- offered with the smaller 25H2 gearhead Whether working with round, prismatic, ing of a chuck and jaw module, no longer featuring a 1-inch hollow shaft and ratios small, or larger components, virtually any compares to the large and heavy vises that from 5:1 to 60:1. The larger 30H3 gearhead workholding configuration is possible with are found in many shops and whose size is features a 1.25 hollow shaft and covers the its modular system. The various workhold- more of an obstacle than an advantage. As gear ratios of 80:1 to 240:1. Bodine hypoid ing adapters can be installed in two minutes is often the case, the workholding is much or less. Hainbuch’s designers and engineers larger than the part to be machined, so inter- in Germany are constantly expanding its ference is an issue. Special, longer tools are modular system to offer the best workhold- then needed and there’s a risk of a costly col- ing solutions. lision. The Hainbuch modular system, on the Something was missing though: an other hand, is just as efficient and flexible as adaptation to clamp cubic parts. That’s why multitasking machine tools are today. Hainbuch introduced the two-jaw module. Round workpieces are clamped from the MORE INFO www.hainbuch.com/en outside with clamping heads (collets) within the collet chuck. Larger diameter workpieces, beyond the capacity of the collet Bodine introduces chuck, can be clamped with the three-jaw module. For cubic parts that are positioned compact hypoid centrically on machining centers and milling machines, the new two-jaw module is PMDC gearmotors now an option. Operators can change over Bodine Electric Company introduces 60 new High-torque, highly efficient type 33A-25H2 and 33A- from clamping round parts to cubic ones in type 33A7-25H2 and 33A7-30H3 hollow-shaft, 30H3 PMDC hypoid gearmotors from Bodine Electric less than two minutes. right-angle hypoid PMDC gearmotors. These Company.

50 gearsolutions.com Custom PreCision Gears Apart from the Crowd

Small droplets resulting from coating parts can negatively affect performance. The auto hone can remove these irregularities, improving performance and preventing chipping. (Courtesy: Bel Air Finishing)

gearmotors are available with low-voltage ing specifications. Following the finishing (12 or 24 VDC), “SCR rated” (90 VDC or 180 process, the robotic arm cleans the part VDC), and standard (130 VDC) windings. within the optional ultrasonic cleaning sta- Rated torque ranges from 20 lb-in (2.2 Nm) tion and can also dry the part in the optional to 1535 lb-in (173 Nm). drying station before placing the part back Hypoid gearmotor accessories include into the tray. The AutoHone is capable of shaft kits, shaft cover kits (non-extension processing parts in as little as five seconds. side), base/foot mount brackets for both It can also extend the life of cutting tools gearheads, and an optional screw-in encoder by up to 300 percent. This applies to both shaft and encoder mounting options. coated and uncoated parts. Tool honing From Bevel to Worm Gears Bodine PMDC Hypoid gearmotors and with the AutoHone reduces the friction of their corresponding accessory kits are avail- cutting tools by removing microscopic burrs Prototype to Assembly able through Bodine’s extensive distributor and sharp edges increasing cutting speed network or from the Bodine website. Custom and providing a surface that coatings can Aerospace to Medical options are available to qualified OEMs. adhere to better. When pre-coated pieces are Typical OEM modifications include factory honed, the AutoHone removes microscopic installed encoders or brakes, custom wind- irregularities on the surface of the tool. Southern Gear ings or wire harnesses, application-specific These irregularities happen when parts are mounting options, or higher degrees of envi- coated and the coating is unevenly distrib- iS your ronmental protection. uted across the part’s surface. The removal of these irregularities reduces the friction of CuStom PreCiSion MORE INFO www.bodine-electric.com cutting tools on surfaces and increases the cutting speed. Gear SourCe The AutoHone has been used in almost Bel Air develops every industry to process medical, automotive, aerospace, fire arms, machined parts, automated robotic and 3D-printed parts. It is available with options to better adapt to any manufactur- deburring machine ing environment. Bel Air can process sam- Bel Air Finishing has developed The ples of parts at its facility. AutoHone, a state-of the-art reverse drag Southern Gear finisher. Unlike traditional drag finishers, MORE INFO belairfinishing.com the reverse drag finisher rotates media instead of parts. It then dips parts into the (800) 248-5152 flowing media held within a rotating bin. AEM hails USMCA The AutoHone combines this with robotic southerngear.com automation, enabling a turnkey solution for benefits to equipment to deburring, polishing, cleaning, and drying. The unique robot arm enables five manufacturers Established in 1957 Veteran-Owned dimensional motions, meaning parts can Association of Equipment Manufacturers be inserted into finishing media at unique (AEM) President Dennis Slater issued the ISO 9001:2015 AS9100D ITAR Compliant angles tailored to achieving specific finish- following statement as the United States-

August 2020 51 PRODUCT SHOWCASE

Mexico-Canada Agreement (USMCA) entered by Chairman Richard Neal (D-Mass.) and into force : the nine members of the House Democrats’ “The USMCA entering into force today Trade Working Group, and ran an ongoing is great news for equipment manufactur- public education campaign on the various ers and our industry’s 2.8 million men and benefits of a ratified USMCA. women working across the United States The International Trade Commission and Canada. This marks the start of a new reported last year that the implementation chapter for North American trade. USMCA of the USMCA could add up to$68 billion to expands agricultural market access, estab- the U.S. economy and create 176,000 jobs. lishes rules for e-commerce, strengthens labor and environmental protections, and MORE INFO www.aem.org updates customs rules that will cut red tape and make it easier for U.S. manufacturers Oelheld’s SintoGrind HSS-X 1400 is formulated with to sell to their Canadian and Mexican cus- Oelheld has new modern GTL (gas-to- liquid) base oils. (Courtesy: tomers. We applaud President Trump, Vice oelheld) President Pence, Senate Majority Leader grinding fluid McConnell, and House Speaker Pelosi to get mineral oil-derived base oils. Gas-to-liquid this agreement to the finish line.” for HSS manufacturers oils are superior in longevity and high- AEM was an ardent supporter of the HSS customer response to oelheld’s new temperature tolerance. SintoGrind HSS-X USMCA since it was first proposed. The SintoGrind HSS-X 1400 grinding fluid has 1400 is suitable for flute-, thread-, profile-, association actively advocated for the indus- been enthusiastic, indicating manufactur- internal-, and external-cylindrical grind- try’s priorities with U.S. and Canadian gov- ers may have felt neglected by the grinding ing of steel materials such as HSS, PM, and ernment stakeholders, participated in the fluid manufacturers. A performance grind- medical steels. SintoGrind HSS-X 1400 is low USMCA Coalition, co-hosted the Honorable ing oil can have a huge impact on production foaming, prevents surface burning, inhibits Mike Pence, Vice President of the United efficiency and output. burr development, is low misting, and offers States, at an equipment manufacturing SintoGrind HSS-X 1400 is formulated excellent filterability. facility in August 2019 to raise public sup- with modern GTL (gas-to- liquid) base oils. port for the agreement, supported the work GTL oils do not display the negatives of MORE INFO www.oelheld.com

MANUFACTURING GEARS SINCE 1920 PRECISE. POWERFUL. PRODUCTIVE. Specializing in manufacturing precision gears, racks, splined kapp-niles.com components, and sprockets for a diverse range of industries.

REISHAURER RZ550 GEAR GRINDER

 State of the art capabilities in gear grinding.  Bias control, Fine grinding, polish grinding.  Prototype to small volume JUST ARRIVED! production.

MITSUBISHI ST40A CNC GEAR SHAPER

 CNC gear shaping up to 15”.  Programable helical guide.  Crown and Taper shaping up to 15 degrees.

Other capabilities include: CNC Gear hobbing up to 20”, EDM Wire and Sinking, broaching, large gear hobbing and shaping.

ONLINE kawoodgear.com CALL FOR FREE QUOTE EMAIL [email protected] 248-585-8870

gearsolutions.com KISSsoft Release 2020 offers additional ways to assess gearboxes The new KISSsoft Release 2020 contains numerous innovations — including additional methods for reliability assessment of your gearbox concept. Now that, in addition to safety factors, results in the form of a time- Seco Tools has expanded its line of square shoulder milling cutters with the Double Turbo. (Courtesy: Seco Tools) dependent survival probability or reliability are increasingly required, KISSsoft also geometry. For the highest level of productiv- The ZOMX16 inserts have high, positive provides the calculation methods according ity, the tools use double-sided inserts with geometries for effective chip evacuation and to AGMA 6006 and VDMA 23904 in addi- four cutting edges and state-of-the-art Seco reduced cutting forces. These features min- tion to the Bertsche calculation method. Tools milling grades. imize vibrations for extended tool life and The calculation procedure is available for The Double Turbo meets the needs of smooth surface finishes. The double-sided individual damage mechanisms, compo- both job shops and mass production facili- design provides significant cost-per-edge nents, subsystems, and entire gearboxes. ties. This system features a highly accu- savings. The ZOMX16 inserts include two This allows, for example, maintenance rate geometry with the most positive helix geometries, ME10 and M12, and two radii, plans to be created, spare parts inventory to angle possible to reduce the likelihood of 0.8 and 1.6. Both PVD and Duratomic® CVD be optimized, or even two gearbox variants surface mismatches and enable impressive grades are available. to be compared using a holistic approach. 90-degree angle accuracy. With such preci- The Double Turbo square shoulder cutter KISSsoft will introduce customers sion, finishing cycle times are significantly design uses materials and resources with to further release highlights in the shortened or, in some cases, completely elim- greater efficiency, resulting in a reduction future. To stay up to date, register for inated. Double Turbo cutters are available in of greenhouse gas emission (CO2) for a more the KISSsoft News, which will be sent by 19 metric variants ranging from diameter 40 sustainable and responsible choice. email approximately every three weeks. mm to 125 mm and 16-inch variants ranging If you are already a customer with a main- from 1.50 inches to 5 inches. MORE INFO www.secotools.com tenance contract, you should have received the update in July. Precision Mechanical Components & Assemblies Standard Industrial Components | Made To Print Parts MORE INFO www.kisssoft.com

KISSsoft Release 2020 provides new calculation methods in addition to the Bertsche calculation method. (Courtesy: KISSsoft) Seco Tools adds double turbo square shoulder Gears, Pulleys, Shafts, Bearings, Couplings, Fasteners, Custom Gear Boxes Value Added Features and Services mills, inserts Engineering, Refurbishing & Design  Press bearings into pulleys ADD Custom Made To Print Parts  Assemble bearings to shafts • Grooves • Flats • Keyways • Pins For manufacturers who struggle to achieve Modified Standard Parts  Set backlash on gears • Threads • Staking • Pressing  Assemble drive boxes • Testing superior part surface finishes without high Assemblies & Sub-Assemblies  Straightening machine power consumption, Seco Tools Custom Mounts For Shafts has expanded its industry-leading line of  Welding Build Sub-Assemblies And  Kitting square shoulder milling cutters with the Complete Assemblies  Plating / Custom Coating Double Turbo. The cutters improve roughing Prototype Work  Heat treat operations and reduce power consumption Nordex.com [email protected] [email protected] in steel, stainless steels, cast iron, and high- Phone: (800) 243-0986 or Call: (203) 775-4877 temperature alloys with an advanced cutter

August 2020 53 KORO for Quality MARKET Hob Sharpening Service  Quick Turnaround 2 Day Service  PLACE Spur Shaper Cutter Sharpening · Custom gear racks in AMERICAN and  METRIC standards, STRAIGHT and HSS & Carbide Hob with center hole HELICAL, VARIOUS materials, FINE and and straight flutes COARSE pitch (254 D.P. – 0.5 D.P.; 0.10  Module – 50 Module); hard-cut (up to Contact Gear Solutions Thin Film Coatings 60 Rc) and soft-cut (up to 40 Rc); 32”  Length up to 7 inches face width; Up to 82” lengths – longer at 800-366-2185 to lengths through resetting · Custom gears in AMERICAN and feature your business METRIC standards (3 D.P. – 72 D.P., 10”  Diameter up Diameter) to 5 Inches · Precision Quality up to AGMA 12 in the Marketplace! · Prototype & Production quantities  Precise rake · Breakdown Service Available and spacing guaranteed · Reverse Engineering · Unique Tooth Configurations to AGMA standards · Heat Treating  RUSH SERVICE AVAILABLE · Complete CNC Machining Koro Sharpening Service 9530 85th Ave North Maple Grove, MN 55369 763-425-5247 [email protected] WE’RE CERTIFIABLE Our ISO 17025 A2LA Laboratory is available REACH MORE to certify or recertify your Master Gears and Spline Gauges or Contract Inspection of your gears. Our rapid turnaround service minimizes the CUSTOMERS “out of service” time. Advertise with us in print and online, and you can reach over 45,000 potential readers – many who are key

6161 Webster Street, Dayton, Ohio 45414 decision makers at their companies. 937-660-8182 [email protected] www.gearinspection.com

PRECISION GROUND RACKS AND PINIONS

A.G.M.A. Class 12 or Better CAPABILITIES  Rack Cutting/Grinding up to 192” To learn more, contact national sales manager  64 Pitch down to .625 Pitch  Surface Grinding up to 144” Dave Gomez at [email protected]  CNC Milling up to 120” or call 800.366.2185 ext. 207 18235 Weaver St., Detroit, MI 48228 Ph 313-836-4131  Fax 313-836-1023 Email [email protected]

gearsolutions.com ADVERTISER INDEX CONTENTS PAGE NO.

ALD Thermal Treatment Inc...... 2

All Metals & Forge Group...... 9

American Precision Gear Co...... 11

Amorphology...... 15

Circle Gear & Machine Co Inc...... 17

Forest City Gear...... IFC

Innovative Rack & Gear...... 54

Kapp Technologies...... 14, 52, 55

Ka-Wood Gear & Machine...... 52

KISSsoft USA LLC...... 14

Koro Sharpening Service...... 54

McInnes Rolled Rings...... 13 PRECISE. POWERFUL. PRODUCTIVE.

kapp-niles.com Mitsubishi Heavy Industries America Inc...... BC

New England Gear...... 7

Nordex Inc...... 53

Penta Gear Metrology LLC...... 12, 54

Piselli Enterprises Inc...... IBC

Russell Holbrook & Henderson Inc...... 11

Southern Gear & Machines...... 51

STD Precision Gear & Instrument...... 18

Tech Tool Company...... 54

The Broach Masters Inc...... 4

Toolink Engineering Inc...... 1

United Tool Supply...... 55

August 2020 63 Q&A DANIEL WEIS INTERVIEW WITH AN SALES TEAM LEADER  NEUGART USA INDUSTRY INSIDER

“Our NGV gearbox caters toward the special applications in the AGV market segment focusing on special features.”

How long have you been with Neugart and what are your How have you made inroads in the U.S. market for this product? responsibilities? We have already served some of the demand out there with our I started my career with Neugart in 2005 as a young mechanic standard products, but, since our NGV product launch, the customer apprentice on the shop floor learning all the tricks of the trade and response has been very enthusiastic, and we are getting more and gaining in-depth technical knowledge in CNC machining particular- more opportunities and acquiring new business. We are, of course, ly for geared parts. After the four-year apprenticeship, I furthered my working with our market specific OEMs and system integrators to education, earning a Bachelor’s and Master’s degree at the University supply the increasing demand. It’s really been taking off since this of Applied Sciences in Offenburg, Germany, before re-joining the year, despite the pandemic. Neugart family in the sales department as technical liaison to our U.S. subsidiary. In 2015, I took the leap and relocated to the newly Is the marketing in the U.S. different than how Neugart markets built Charlotte, North Carolina, facility where I will soon celebrate in Europe? my five-year work anniversary in this location. Here I work as Sales I have actually spent more time as a professional in the U.S. than Team Leader, helping our North American partners and customers in Europe but can definitely attest to the different marketing prac- find the perfect gearbox solutions, and I actively define strategies to tices. Obviously, the U.S. and European market are two similar but explore new and existing business opportunities, including in the distinctly different economies, and so the marketing has to adapt to AGV market. that. In our terms, our marketing strategy has always focused on our core values of the precision and quality of being a German gearbox Give us an overview of the gearbox Neugart is using the AGV manufacturer, and, of course, we always have the customers’ benefits market and what makes it unique. in mind. That does not change across borders and is a universal thing The AGV market has existed for quite a while, and we had been in the Neugart world. historically using our standard product portfolio and some customized gearbox options to satisfy the emerging market. Realizing You mentioned briefly what the U.S. response has been. Would that our standard portfolio was well suited but not ideal for many you like to expand on that? conditions, our product management team analyzed the market Since the introduction of this special NGV gearbox, the market requirements and developed an industry specific gearbox solution. response we’ve received through print and online media has been Our NGV gearbox caters toward the special applications in the AGV really great. We’re working currently on several opportunities, and market segment focusing on special features like high load bearings I hope soon that we will have some white papers with customers to support high payloads, energy efficiency, and compactness to help that we are able to share to create more marketing and future sales AGV designers get the most out of their space, and we also feature a opportunities through this. recessed mounting surface for ease of assembly. In addition to that, we also offer a high load bearing accessory wheel for each size of the offered product as well as simulation and sizing software to test and www.neugart.com verify the design specifications. MORE INFO

The Neugart Guided Vehicle gearbox is a design-specific solution for the AGV market segment of self-driven vehicles. (Courtesy: Neugart)

gearsolutions.com 2006 Reishauer Model RZ-400 CNC Generating Style Gear Grinder

2007 Samputensili S-750 Gear Hobber

2007 Liebherr Model LFS-380 6 Axis CNC Gear Shaper

2007 KAPP KX-300P CNC Gear Grinder 2006 Gleason M&M System Sigma 3 2004 Gleason Model 600 HTL CNC Turbo Lapper Fanuc 160i-M Controller

1 left

2005 Gleason Pfauter Model GP-150S Bourn & Koch Model 25H 4 Axis 2001 Hofler Model Helix 700 2006 Mitsubishi Model SE25A CNC CNC Gear Shaper CNC Horizontal Gear Hobber CNC Gear Grinder Gear Shaper with Autoloading

820 Cochran Street Statesville, NC 28677 THE #1 SOURCE FOR YOUR USED MEMBER 704.609.0766 • [email protected] www.pisellient.com GEAR MACHINERY — AND MORE! MEMBER Our Technologies, Your Tomorrow

We have the power to make your business a force

Gear Machines That Drive Business Forward With Mitsubishi’s full line of proven gear machines delivering incomparable reliability, performance, flexibility and quality, you can turn your production and cost controls into a force to be envied. These machines offer an array of options that are sure to satisfy any demand, including machine diameters ranging from 60mm to 2000mm and processes for hobbing, shaping, milling, chamfering, deburring, shaving and grinding—all with or without automation. Don’t hesitate to contact us for assistance; our fast engineering response team is ready to provide the world class performance of Mitsubishi gear machines at www.mitsubishigearcenter.com or contact sales at 248-669-6136.