Now there are no limits to how good aU iiiiiiiiii:!~our gears can be. Chances are there's a Gleason Malu metrology product for any and all of your gear and gear tool measuring requirements: bevel or cylindrical, internal or external, plastic or formed, hobs or shaper cutters. Call today or log-on Now you have single to learn more ••• sourc,e ac,cess... to everything www ..-Ieason ...com from Double Flank Roll Testers to accurately identify proce 5 variations on the shop floor. on the fly' to the PR[MAR Universal Gear Inspection System: the 1000 U niversity Ave .• p.o. Box. 229'70 latest in single setup complete measuring Rochester, NY 14692-2970 U.S.A. technology, Phone: 585/473-1000 Fax: 585/4614348 Web site: wwwgleason.eom E-mail: [email protected] TH.ELAT£5T INNOVATION fNHOBBING. SUPERIOR QUAUTY. SERVICE AND Dfl.lVER Y. MAV/JUNE 2002 The Journal 0/ Gear Malzu/acturi'ng FEATURES Carbiide H!obbing Case Study A gear manufacturer starts from scratch with new technology ,.., , 12 FOCUS ON GEAR DESIGN Gear Oesiign Spec;ial Section , 21 Optimizing IPlastic Gear Geometry: An Introductiont'D ,G,earOptimizat~ion A close look at working tooth depth and other parameter , , 22 Program for Involut,e Equat.ion to. Develop, Spur Gears, on Pm/E Software A program for modeling spur gears with profile shift ,.., , ,., 27' 21' lnereased Load 'Cap,ady of Worm Gears by Optimizing the Worm Wheel Bnm~e A study of bronze alloy content.. " 33 DEPARTMENTS IPublisher~s Page, lndu trial Evolution 7 Revo~lutions Ice-blast gear cleaning 9 Industry N'ews Wllat's happeningin the gear industry 18 Technical,Call,endar DOIl'I mi s these important upcoming events 31 IProduct INews The latest product for the gear industry 38 1CD'~RO'MIIB'UyersGuide FRE.EListing Forms Sign up for fr~e listings in our 2003 directory 40 Advertiser Index NEW! Phone numbers and web addresses to make it easier to get information " 44, ICl'assi,lieds Services, Help Wanted, websites and more 45, Clrver art ,CQu:rtesy' 'D. Stepan A'ddendum Lunin, Chesapeak,u'. VA. From Rus ia, With Teeth , 48 _________GEAR' TECHNOLOGYTI!.rJo!!n!{dvffJt(t,.l,l-.Llt"flU{~rin&l_ I I EDITORIAL I Publisher & Editor-In-Chief Michael Goldstein Managing Editor William R. Stott Associate Editor Joseph L. Hazelton Assistant Editor Robin Wright Editorial Consultant Paul R. Goldstein T,echnicaI Editors Robert Errichello Don McVittie Robert E. Smith Dan Thurman ART Art Director Jean Bartz AOVERT1SING Ultra Precise Hobs RUSSE:L:L. Advertising Manager Patricia Flam Accu racy Class: MA, AA, A Ad.vertising Coordinator Gladyce J. Cooper Materials: Carbide/Bridge/HSS tlO:LBROO:K& Tedmology: Dry/High Speed/Hard Hobbing Range: 10-500 Diametral Pitch H'ENDERSON.INC. 17~17 Route 2Q8 North, FiiorrLawn. New Jersey 07410 Cirenlation Coordinator Dina Krauss STOCK AVAILABLE Telephone: 201-796-5445 Fax: 201·796·5664 ~ MEMBER OF ~WM!,II; GROuP INTERNET Visit our website at: http://www_tru-volute.com Web Developer Dan Mackenzie Gear Industry Home PageThI Sales Patricia Flam David Tornalis powertrallsmission.COIII™ Sales Michael A. Gianfrancesco RAND'.AU PUBLISHING STAFF President Michael Goldstei 11 Vice President Richard Goldstein Controller Michael Grafma.n Accounting Dianne Johnson Phone: 847-437-6604 E-m.ail: people@gearteclmology,com Web: www.geaneehnelogy.com www.powertransmission.com BPA W VOL 19, :NO.3 ,GEAR TECHNOLOGY, The Journal or Geu" Mailula.t-"tln~ (fSSN 0743-(,858) is published hirnonthly by Randall Publishing. Inc, 1425 LUi1t Avenue. ,P.O. Bo, 1426. Ell< Grove Village. IL 6IJO()7,(847) 437-6604. Cover price $5.00 U.S. Periodic. I postage pnid at Arlington Heights, [L, and at additional mulling office. Randall Publishing makes every effort to ensure thai the proces-se!i described in GEAR TECHNOLOGY conform to sound engi- neering practice. Neither the authors nor the publisher can be __ , tnchldngtlnlla atament. held responsible for injuries susruined while following the procedures described. Postmaster: Send address changes to Atrow's latest success was utilizing our GEAR TECHNOLOGY. The Journal of Go ur Manusacun-ing. 1425 Luru Avenue. P.O. Box 1426. Elk state-of-the-art technologies to design the Grove Village, IL, 6IJO()7.OConLont. copyrighted by RAN- gear tooth geometry and to manufacture DALL PUBLISHING, INC .. 2002. No pan of Ilti. publico- 2301 Curtiss Street. Downers Grove.IL 60515 lion may be reproduced or transmitted in .un)' form or by any all bevel gears in the PTO&AGB for meansc electronic or mechanical, including photocopying. Tel: (630) 969·76.40 • Fax: (630) 969-0253 recording. or by uny ill format jon storage and retrieval sys- Pratt & Whitney's PW 6000 engine. www.ar.lOwgear.com tem, without permlssron In writing from me publisher. Contents of ads arc subject 10 Publisher's approval. 4 MAY/JUNE 2002' GEAR TECHNOLOGY" WWW.geartechnolagy.com' www.powertransmlssian.com See Us at NACHi Booth # B6953 NACHI MA.CHINING TiECHNOI.;OGY co. 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New & Improved Dura-Bar Plus gives you A LOWER COST PER PART ••• PLUS - MORE PARTS PER HOUR! Decrease cycle time. Increase productivity! PLUS - LONGER INSERT LIFE! Reduce your downtime for tooling changes! PLUS - A DEFECT-FREE MATERIAL! Quality guaranteed! New Dura-Bar Plus is available in gray and ductile iron grades and in a wide variety of sizes and shapes. For more information, see web site at www.dura-bar.com, Or can i-800-BAR MILL (1-800-227-6455) AND SAVE MONEY WITII New Dura-Bar Plus, mE LATEST IN ENGINEERED METAL TECHNOLOGY. Continuous Cast Iron Bar Stock 21.00 West. Lake Shore Drive, Woodstock, II.. 60098-6911 1-800-BAR-MII..I.. • 815-338-7800 • FAX: 815-338-.1549 ' E-mail: [email protected] Internet: www.dura-bar.corn .. .' IPUBUSH.ER'S PAGE 1----------------- he gear j'ndustry. m(e any Olher, is constantly chang- of nron Corp.. whose wind turbine division was a major cus- ing. Companies vie for customer, resources, tomer of Cincinnati Gear. On Feb. 28, , incinnau Gear was employees. and time. They come, go and shuffle for forced to layoff most of its employees. T po ition, Usually, the changes are small, affecting According to a letter we received from 'the company in late only a few companies. But sometime, many March, Cincinnati Gear is working with a management consult- changes happen at once, and when those changes arc large. it ing firm (0 "explore all available option [Q maximize the value can seem as though an earthquake ha struck and transformed of its business and assets." What this mean at this time i . the landscape of the industry. unclear, but what is clear is I feel as if such an earthquake ha recently truck, TwO' that if Cincinnati Gear month of tumult haveleft us with a different gear industry than emerges from these diffi- we had the last time m wrote thi column. In particular, two old culties, it will be a much friend have dosed their doors. Also, we've seen realignment leaner company than it once among some of the key suppliers. was. We were addened to hear that one of the gear industry's old- We've all watched the e 'I upplier -Fellows Corp.-was forced [Q clo e its doors in manufacturing economy February. Located in. orth Springfield, VT, Fellows served the struggle over the past two gear industry for more than 100 years. It was founded in l 896 years. We've seen it COIl- by Edwin R. Fellows, the inventor of the American version of tract, as Americans have imported more of the manufactured the gear haping machine, goods we used to make for ourselves. It's no surprise then that Fellows cia ed when it parent company, the Goldman some gear industry companies are having problems and have ;Industrial Group, filed for Chapter 11 bankruptcy protection. been laying off employees over the past couple of years. Goldman' Bridgeport Machine Co. continues to operate. but the Hopefully, the companies that. urvive these times-c-perhaps group's other sub idiarie , Bryant Grinder, Hill-Lorna ]nc .., J&L including ellows and Cincinnati Gear-will be in much better Metrology and Jones & Lam on Machinery, closed along with position to take advantage of the market when it improve , Fellows. Those dosed subsidiaries are now up for sale. In the face of slower manufacturing actjvity. plana are clos- Hopefully. someone who wants to continue making gear ing and new. foreign suppliers from places like India, Pakistan, machine tool will buy Fellows so that the name doesn't fade Poland, China, Taiwan and South Korea are taking their place, into obscurity. This process is not unique tothe United States. England. the Shortly after we heard the news about Fellows, we were birthplace of the Industrial Revolution, is seeing an exodus of shocked to learn thai.