GEJULY/AUGUST 2006AR TECHNOLOGY The Journal of Gear Manufacturing www.geartechnology.com THE GEAR INDUSTRY’S INFORMATION SOURCE We get through our day... by helping you get through yours. Bourn & Koch’s Fellows Star SU Gear Hobs & MS450-125 CNC Gearless Milling Cutters See Our Gear Shaper with CNC controlled guide NEWEST INNOVATIONS at IMTS 2006 Bourn & Koch 100H CNC Star SU Gear Shaper Cutters Horizontal Hobbing Machine – ideal for hobbing multiple splines and gears on shafts with tandem mounted hobs and milling cutters. Samputensili S250CDA-CF Star SU Gear Shaving Cutters CNC Chamfer Deburr Machine Star PTG 1 CNC 5 Axis Star SU Gundrills & Reamers Hob & Shaper Cutter Tool Resharpening Machine – gives you the additional capability to sharpen form relief cutters, end mills, drills and step drills. Includes NUMROTO software and quick change tooling. Star PTG 4 CNC 5 Axis Star SU PCD Rotary Tool & Cutter Sharpening Cutting Tools Machine – has an automated 4-station wheel and coolant manifold change system, HSK quick release grinding wheel pack and includes NUMROTOplus software with Vericut 3D visualization. : We innovate. You implement. We get through our day... by helping you get through yours. See Our NEWEST INNOVATIONS at IMTS 2006 September 6-13, McCormick Place, Chicago Star SU Padded Reamers and Fine Boring Tools Star SU Carbides for fl uted preforms, fl at blanks, cold-head dies and bushings, round rod, gundrill blanks, special extruded shapes, wear parts and punches Star SU Bevel Stick Blades Star SU Total Tool Life Cycle Management (TLCM) saves on your tool costs while eliminating tool management headaches Star SU – Balzer Applied Coating Technology enhancesenhances your cutting processes and reduces your overall tool IMTS cost-per-part. Booth No. B-6912 September 6-13, 2006 McCormick Place Chicago, IL Member AGMA Star SU LLC 5200 Prairie Stone Parkway, Suite 100 : Hoffman Estates, IL 60192 Tel: 847 649 1450 Fax: 847 649 0112 We innovate. You implement. www.star-su.com JULY/AUGUSTGE 2006AR TECHNOLOGY The Journal of Gear Manufacturing AUTOMOTIVE GEARS New Transmissions Drive Automotive Gear Industry The latest news on car transmission manufacturing……….............................................18 Trends in Automobile Transmissions 18 Perspectives from a leading manufacturer ………………………………………….......24 TECHNICAL ARTICLES Generating Interchangeable 20° Spur Gear Sets with Circular Fillets to Increase Load Carrying Capacity Research demonstrating circular fillets can be stronger than trochoidal fillets………....28 The Lubrication of DLC Coated Gears with Environmentally Adapted 36 Ester-Based Oil How do oils for steel fare when used on gears with diamond-like coatings?...................36 How to Achieve a Successful Molded Gear Transmission Quality molded gears begin with the mold……………………………………………..42 42 DEPARTMENTS Publisher’s Page Who Pays Your Salary?......................................................................................................7 Product News New grinding wheels, a new thread grinder, and other products for the gear industry......9 IMTS 2006 48 An overview of the upcoming manufacturing event……………………………............48 GEJULY/AUGUST 2006AR TECHNOLOGY The Journal of Gear Manufacturing www.geartechnology.com Events A metal gear course and our technical calendar...............................................................54 Industry News The latest from the gear industry......................................................................................56 Advertiser Index Use this directory to get information fast..........................................................................61 THE GEAR INDUSTRY’S INFORMATION SOURCE Classifieds On the cover: GM's 6L80 6-speed Services, Forgings, Heat Treating and Gear Manufacturing.............................................62 transmissiontransmission (illustration(illustration byby David Kimble); the 2007 Saturn Addendum Aura; and the 2007 Lincoln MKX. A Movie for Gearheads and Other Mechanical People.....................................................64 2 JULY/AUGUST 2006 • GEAR TECHNOLOGY • www.geartechnology.com • www.powertransmission.com We do. � Discontinuous generating grinding � Dressable and CBN tools � On-board inspection � Integrated balancing � Compact, ergonomic designdesign � Siemens 840D control Come to booth B-7030 to see the Turnkey Machine!Machine! KAPP Technologies 2870 Wilderness Place Boulder, CO 80301 Ph: 303-447-1130 Fx: 303-447-1131 www.kapp-usa.com [email protected] KAPP ) niles ��������������� A/W Systems Co. is your quality alternative manufacturing source of spiral gear roughing and finishing cutters and bodies. We� can also manufacture���� new spiral cutter bodies�� in diameters���� of 5" through 12" at present. A/W can also supply roughing and finishing cutters for most 5"–12" diameter bodies. Whether it’s service or manufacturing, consider us as an alternative source for cutters and bodies. You’ll be in for a pleasant surprise. Visit us IMTS Show 2006 Booth #B-7112 1901 Larchwood Troy, MI 48083 Tel: (248) 524-0778 • Fax: (248) 524-0779 PUBLISHER’S PAGE Who Pays Your Salary? I just finished conducting annual As a publisher, while my first reviews with our employees. About concern is not individual automobile this time, I meet with each employee consumers, their wants and needs to review progress and goals from the ultimately play a role in our decision- past year, set new goals for the coming making process. For example, when year and review the financial perfor- we choose to run a technical article mance of the entire company. on gear noise, doesn’t it ultimately These reviews are a useful opportu- benefit the end consumer? nity to get feedback about what is work- Ultimately, a business has to pay ing and what isn’t, from the employees’ attention to his complete chain of perspectives. We ask for suggestions customers, from the one who pays about what we and they could and him directly to the one who ulti- should do better. Some of the best decisions we’ve implemented mately uses the end product. Of course, the ones closest to us have come out of these meetings. on the chain are the ones we have to pay the most attention to, Of course, the employees are always interested to know but often we can best serve them by thinking down the chain to whether they’ll be getting raises or bonuses—and if so, how the next level. much. But while conducting reviews this year, I found myself In our annual reviews, I encouraged each of my employees explaining the idea that their salaries, raises and bonuses really to think about our customers and how we can better serve them don’t come from the company—or from a specific individual. and to consider new ways to make our customers more success- They, we—all of us—get our paychecks from our customers. ful with our products. Of course, customers don’t come to us and buy our products But this isn’t an exercise just for publishers. The idea holds and services because of their concern for our welfare or the true in many businesses, including gear manufacturing. welfare of our families. Customers come to us because they So, who really is your customer? How can you make him need our products or services to help them solve a problem or more successful with your products? How far down the chain accomplish something they couldn’t do themselves. If we don’t are you thinking? Have you thought about your customer’s provide these products and services to our customers, at prices customer lately? If not, I encourage you to do so. After all, it’s they can afford, they will find suppliers that do. not your boss who pays your salary or who decides if you get In publishing, our first contacts are the advertisers. I need a raise. Ultimately, it’s the customer who does. Concentrate on those companies to be successful using this product. To accom- making him successful with your products and services, and plish that, I spend a lot of time thinking about their customers everyone benefits. (that would be you guys, the readers). If we didn’t have infor- mation of interest to you, the readers, and if we didn’t deliver the magazine to you, then our advertisers would have no eco- nomic reason to advertise. Thinking about this concept, I started to wonder, Who really is the customer? The first reaction is that the customer is the company to whom we directly sell or ship our products. But in Michael Goldstein, fact, the real customer may be farther down the line. Maybe it’s Publisher & Editor-in-Chief your customer’s customer who is the end user. You can follow that line of reasoning until, eventually, you get back to individual consumers. You might not think Gear Technology has much to do with the average person, but in fact, it does. For example, our magazine sells advertising to a gear machine tool manufacturer. The machine tool manufacturer sells his products to an automobile transmission manufacturer. The transmission goes into an automobile that eventually ends up in a consumer’s driveway. And the chain might even become a circle if that consumer is one of my employees, or even me. www.powertransmission.com • www.geartechnology.com • GEAR TECHNOLOGY • JULY/AUGUST 2006 7 ANNOUNCING! GCS “Gear Cutting Systems” Division ● Carbide Grades Available ETC-809 (Specially Formulated for Dry Cutting Bevel Gears) as well as Equivalent Grades to KC7315 & H10F ● HSS Grades Available REX 76, M4, ASP30 Sales & Service, Ned Hoermann [email protected] Cell: (314) 623-5395 ● Balzers BALINIT PVD Coatings Director of Operations,