MAY YEARS of 2016 GEARS 100AGMA's Centennial Celebration Q&A with Joe Franklin The Gear Industry Needs You Make Volunteering the Norm MULTI-AXIS MACHINING IN GEAR MANUFACTURING TECHNICAL How to Make the Best Bevel Gears Noise Reduction in an EV Hub Drive www.geartechnology.com THE JOURNAL OF GEAR MANUFACTURING Solutions for all your gear cutting tool needs Gear cutting tools and services • Master gears • Ring and plug gauges Star SU offers a wide variety of • Advanced coatings including ALTENSA and gear cutting tools and services, including: ALCRONA PRO • Tool re-sharpening • Gear hobs • Milling cutters Total tool life cycle management • Indexable Gear Milling Solutions by Sandvik Coromant Control your tool costs and let Star SU manage your • Shaper cutters tool room. From new tools to design work to re- ® • Scudding cutters sharpening and recoating, we have the equipment • Shaving cutters and resources to help keep your gear cutting operation • Chamfer and deburring tools running smoothly. • Rack and saw cutters Phone: 847-649-1450 5200 Prairie Stone Pkwy. • Ste. 100 • Hoffman Estates • IL 60192 2016-04_Star-SU_Adv_2pages_us.indd 1 05.04.16 00:29 Solutions for all your gear cutting tool needs Affordable hob sharpening and in-house tool maintenance Star’s PTG-1L linear motor driven machine sharpens both PTG-1L straight and spiral gash hob designs up to 8” OD x 10” OAL. Additionally, it sharpens disk, shank and helical type shaper cutters, Scudding® cutters, and a wide range of round tools, making it a versatile tool room machine. Shaving cutter and master gear grinding Designed to grind shaving cutters and master gears, the GS 400 sets new standards for precision, reliability and ease of use. An integrated measuring unit automatically checks the quality of the GS 400 fi rst tooth ground without unclamping the workpiece. System technology from one source www.star-su.com 2016-04_Star-SU_Adv_2pages_us.indd 2 05.04.16 00:29 contents MAY ® 2016 38 KAPP NILES machines efficiently finish-grind your critical gears and profiles with an accuracy of one thousandth of a millimeter, and a diameter of up to eight meters, to the utmost precision and durability. 28 features technical 24 The End of An Era — Joe Franklin’s Valedictory 30 Ask The Expert AGMA President Joe Franklin is Stepping Two Idler Gears? Down after 24 years on the Job. 44 Noise Reduction in EV Hub Drive Using Full Test and Simulation Methodology 28 Off-Highway Endures Soft Markets A series of tests and advanced simulation to Outlook Not Yet Truly Grim — but Companies troubleshoot and optimize an EV hub drive for noise are Scaling Back. reduction is presented. 54 (Stadtfeld’s) Rules for Optimal Basic Design of 38 All-For-One, One-For-All. Generating Grinding 8mm- 1,250mm • Profile Grinding 8mm- 8,000mm Advantages of Multi-Axis Machining in Gear Bevel Gears from small to large Making the Best Bevel Gears. Manufacturing. Vol. 33, No. 3 GEAR TECHNOLOGY, The Journal of Gear Manufacturing (ISSN 0743-6858) is published monthly, except in February, April, October and December by Randall Publications LLC, 1840 Jarvis Avenue, Elk Grove Village, IL 60007, (847) 437-6604. Cover price $7.00 U.S. Periodical postage paid at Arlington Heights, IL, and at additional mailing office (USPS No. 749-290). Randall Publications makes every effort to ensure that the processes described in GEAR TECHNOLOGY conform to sound engineering practice. Neither the authors nor the publisher can be held responsible for injuries sustained while following the procedures described. Postmaster: Send KAPP Technologies address changes to GEAR TECHNOLOGY, The Journal of Gear Manufacturing, 1840 Jarvis Avenue, Elk Grove Village, IL, 60007. Contents copyrighted ©2016 by RANDALL PUBLICATIONS LLC. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission in writing from the publisher. 2870 Wilderness Place Boulder, CO 80301 Contents of ads are subject to Publisher’s approval. Canadian Agreement No. 40038760. Phone: (303) 447-1130 Fax: (303) 447-1131 [www.geartechnology.com] www.kapp-niles.com [email protected] 2 GEAR TECHNOLOGY | May 2016 KAPPAd_May-Jul_2016.indd 1 4/5/2016 4:31:55 PM KAPP NILES machines efficiently finish-grind your critical gears and profiles with an accuracy of one thousandth of a millimeter, and a diameter of up to eight meters, to the utmost precision and durability. from small to large Generating Grinding 8mm- 1,250mm • Profile Grinding 8mm- 8,000mm KAPP Technologies 2870 Wilderness Place Boulder, CO 80301 Phone: (303) 447-1130 Fax: (303) 447-1131 www.kapp-niles.com [email protected] KAPPAd_May-Jul_2016.indd 1 4/5/2016 4:31:55 PM contents ® Vol. 33, No. 3 departments NEW 06 GT Extras Release Check out our GT Library and its 30 years’ worth 03/2015 (more than 2,000) of technical articles; also, Basics: cutting tools. KISSsoft Highlights 09 Publisher’s Page Happy Birthday AGMA! ● Risk assessment of flank fracture for cylindrical gears 12 Voices ● Contact analysis for bevel gears Dean Burrows: The Gear Industry Needs You ● Planet carrier deformation with FE calculation 14 Voices ● Housing stiffness in KISSsys T.J. “Buzz” Maiuri: Make Volunteering the Norm ● Modal analysis of shaft systems 18 Product News KISSsoft USA, LLC ● And many more ... 3719 N. Spring Grove Road Gleason 500CB Inspection Machine; Big Kaiser Johnsburg, Illinois 60051 Milling Chuck; Saint Gobain NQ3 Grinding Wheels… Phone (815) 363 8823 Get your free trial version at [email protected] www.KISSsoft.com 64 Industry News AGMA names Croson president; other news of note 68 Calendar of Events May 23–26: Windpower 2016 June 5–8: Powdermet 2016 June 27–29: Made by Klingelnberg Gear Seminar/ WZL Gear Conference (See inside for details.) GearTech_KISSsoft_Rel_03_2015_Highlights_89x120_5mm.indd 1 19.03.2015 15:18:24 69 Subscriptions Sign up or renew your free subscription. 70 Advertiser Index How to find every supplier in this issue 72 Addendum Harvesting Motion Power MAY YEARSof 2016 GEARS 100AGMA's Centennial Celebration Q&A with Joe Franklin The Gear Industry Needs You Make Volunteering the Norm MULTI-AXIS MACHINING IN GEAR MANUFACTURING TECHNICAL How to Make the Best Bevel Gears Noise Reduction in an EV Hub Drive www.geartechnology.com THE JOURNAL OF GEAR MANUFACTURING [www.geartechnology.com] 4 GEAR TECHNOLOGY | May 2016 Liebherr Performance. Economical solutions by New design possibilities for generating grinding of the micro gear geometry modifi cations of the fl ank The same torque at smaller face width TF – Twist-Free Noise reduction DFT – Deviation Free Topological NEO – Noise Excitation Optimized modification GER – Generated End Relief Dresser independent profile modifications Liebherr Gear Technology, Inc. 1465 Woodland Drive Saline, Michigan 48176-1259 Phone.: +1 734 429 72 25 E-mail: [email protected] www.liebherr.com 2014-504_029_LVT_005_Mikrogeometrie_GB_auMP.indd 1 16.12.15 11:56 GT extras THE GEAR INDUSTRY’S INFORMATION SOURCE www.geartechnology.com Unlock the Vault RANDALL PUBLICATIONS LLC The GT Library offers more than 2,000 technical articles published in the 1840 JARVIS AVENUE last 32 years as well as historic profiles on companies like Gleason “Hub of ELK GROVE VILLAGE, IL 60007 the Gear Industry,” (www.geartechnology.com/articles/0115/Hub_of_the_Gear_ (847) 437-6604 Industry), Klingelnberg “The Latest Gear Generation,” (www.geartechnology. FAX: (847) 437-6618 com/issues/1013x/jan_klingelnberg.pdf) and Samputensili “Gear Sample,” (www. EDITORIAL geartechnology.com/issues/0114x/antonio-maccaferri.pdf). Publisher & Editor-in-Chief Michael Goldstein [email protected] Associate Publisher & Managing Editor Randy Stott [email protected] Senior Editor Jack McGuinn [email protected] Senior Editor Matthew Jaster [email protected] News Editor Alex Cannella [email protected] Editorial Consultant GT Featured Topics Paul R. Goldstein Technical Editors The Gear Technology homepage (www.geartechnology.com) William (Bill) Bradley, Robert Errichello, features an in-depth collection of more than Octave Labath, P.E., John Lange, Joseph Mihelick, Charles D. Schultz, P.E., Robert 32 years of technical content. Articles are E. Smith, Mike Tennutti, Frank Uherek indexed by subject, so all you have to do is DESIGN type what you’re looking for in the search bar. Art Director David Ropinski This Month’s Highlighted Topics: [email protected] Basics ADVERTISING Cutting Tools Associate Publisher & Advertising Sales Manager Dave Friedman [email protected] Materials Coordinator Dorothy Fiandaca [email protected] China Sales Agent Eric Wu, Eastco Industry Co., Ltd. Tel: (86)(21) 52305107 Fax: (86)(21) 52305106 Cell: (86) 13817160576 [email protected] ON-LINE Digital Content Manager Kirk Sturgulewski Gear Talk [email protected] CIRCULATION Gear Technology technical editor Stay Connected Circulation Manager and resident blogger Chuck Schultz Carol Tratar weighs in on some important gear Follow us on Twitter [email protected] twitter.com/#!/Gear_Technology Circulation Coordinator topics: Barbara Novak In Slow Times Don’t Last, Chuck dis- [email protected] cusses his optimism for the construc- RANDALL STAFF Connect with us on LinkedIn President tion equipment market and the need www.linkedin.com/groups/Gear- Michael Goldstein to get many infrastructure projects Technology-Magazine-3893880 Accounting going in the United States. Luann Harrold In Observations on Health Care, Chuck Subscribe Online examines the much maligned health www.geartechnology.com/ subscribe.htm care industry after scheduling a minor surgical procedure. [www.geartechnology.com] 6 GEAR TECHNOLOGY | May 2016 Extraordinary People Make the Difference Kevin Chatfield Gear Grinding Leadperson We bought a $1.5 million Grinder just for Kevin New gear machines don’t come cheap. But they’re worth nothing without highly qualified, deeply experienced people to operate them. That’s why we invest in the best – both machines and people.