GE AR SOLUTIONS MAGAZINE MAGAZINE AR SOLUTIONS UNDERSTANDING THE BASIC PRINCIPLES OF POWER SKIVING SKIVING POWER OF PRINCIPLES THE BASIC UNDERSTANDING Understanding the Basic Principles of Power Skiving ISSUE FOCUS Cutting Tools Workholding COMPANY PROFILE: Rochester Gear Inc. APRIL 2017 APRIL APRIL 2017 Your Resource for Machines, Services, and Tooling for the Gear Industry gearsolutions.com 1.Cover-2017-04.indd 1 3/31/17 11:03 AM GEAR FIXTURES ALL OPERATIONS LARGE GEAR PEDESTAL FIXTURES LEADERS ARBORS/MANDRELS in GEAR WORKHOLDING CHUCKS/ COLLETS for Over 60 YEARS PROVEN ROI’S • CASE STUDIES • Design and Build Custom Tooling • Outstanding On Time Delivery • Consultations and Installation • Rush Order Capability • Set Up Reduction Solutions • Attractive Pricing Drewco designs and builds European quality tooling and combines it with short lead-times and attractive prices. Tooling gears from 1” to 1,700lbs. Experts at Tooling Up Familes of Part Sizes USE BE A HERO IN YOUR OWN COMPANY 262.886.5050 | [email protected] | www.drewco.com IS YOUR GEAR DEBURRING STILL IN THE STONE AGE WWW.TOOLINK-ENG.COM • 303-776-6212 Reduce your manual labor and increase productivity with one of our Cutting-Edge 2017 James Engineering gear deburr machines. Please contact Toolink Engineering directly for additional information and to schedule machine demonstrations. First-Time Heat Treater Streamlines Production, Reducing Lead Times by Nearly 85% industry or an expert. As such, all TITAN furnaces are carefully designed and crafted with the end user in mind. “We used to send our products to a local heat treater before bringing them back in-house to finish the production process ... In the end, this strategy just wasn’t working for us. It created long lead times and a convoluted in-house workflow that simply wasn’t sustainable.” Customer Story However, they not only needed a heat-treating system that could run their A manufacturer of Aerospace-grade required processes, but also a company fasteners wanted to streamline their that had the resources to support them production process and shorten lead times throughout the process. This included while still keeping costs low. They realized assistance with on-site installation, expert that to meet their objectives they needed training and timely field support. In the to bring heat treatment in-house. end … While the decision to bring heat treatment in-house made sense, this would be their first vacuum furnace. Ipsen’s TITAN® product line appealed to them as it was built on the principle that everyone can be Discover this customer’s heat treater, whether you are new to the winning outcome: www.IpsenUSA.com/Customer-Stories Download Quick Scan or www.IpsenUSA.com QR Droid app to scan code www.IpsenUSA.com FEATURES Rochester Gear Inc. By Molly J. Rogers With new owners taking over the business in 2007 and implementing strategic changes such as new equipment investments and achieving ISO accreditation, Rochester Gear has the ability to meet customer needs for small- to medium-sized precision gears with shorter lead times while maintaining high quality standards. 28 The Whirling Process in a Company that Produces 32 Worm Gear Drives By Massimiliano Turci and Giampaolo Giacomozzi Whirling is a fast method of producing worms: a toolholder ring, carrying a series of profiled carbide cutters, is set eccentric to the workpiece axis and rotates at a high speed. This paper describes the machining process and presents a case history with a comprehensive view of the time and cost benefits compared to a previous situation with standard machine tools. Geometric constraints in the worm shaft design due to the whirling process are also discussed. Understanding the Basic Principles of Power Skiving 42 By Nicklas Bylund General guidelines and simple mathematics, including ways to calculate spindle speeds, are presented to assist manufacturing engineers and decision-makers in determining if power skiving is a viable solution to manufacture a part. A Look at Expanding Mandrels for Gear Workholding 48 By Timothy Zenoski Expanding mandrels that hold gears between centers are used in the gear manufacturing process, most commonly in gear inspection, where high precision and range of expansion are key benefits. APRIL 2017 3 and Universal Gear Company 1605 Industrial Drive Auburn, CA 95603 Phone: (530) 885-1939 Fax: (530) 885-8157 Call 530-885-1939 or visit www.broachmasters.com DEPARTMENTS 08 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. Mazak To Host Technology and Kadia Further Refines LH Honing Education Event for Midwest Shops Spindles In this section, the premier supporter of gear manufacturing in the United States American and beyond shares news of the organization’s activities, upcoming educational and training opportunities, technical meetings and seminars, standards development, Gear Manufacturers and the actions of AGMA councils and committees. 17 Association 22 MATERIALS 51 PRODUCT 60 Q&A MATTER SHOWCASE Casandra Blassingame Peter C. Glaws DIRECTOR OF EDUCATION STEEL CLEANNESS AND WHY MEASUREMENT MATTERS American Gear Manufacturers Association Highly loaded components benefit from clean steels, (AGMA) but careful measurement — from steel processing to final quality — beyond conventional methods is required to achieve a high level of material performance. 24 TOOTH TIPS Rick Miller DESIGNING HIGH CONTACT-RATIO GEARS While there are many ways to design high contact-ratio gears, the following explains one design method that could be used. 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, 25 HOT 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 SEAT or mechanical, including photocopy, recording, or any information storage-and-retrieval system without D. Scott MacKenzie 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 DEVELOPMENT OF RESIDUAL STRESSES DURING News” material has either been submitted by the subject company or pulled directly from their corporate web MACHINING AND WORKHOLDING site, which is assumed to be cleared for release. Comments and submissions are welcome, and can be submitted to [email protected]. Machining and fixturing prior to heat treatment are among the many potential sources for distortion and residual stress. APRILE 2017 VOLUME 15 / NO. 4 Cover: Sandvik Coromant APRIL 2017 5 EDITOR'S LETTER David C. Cooper PUBLISHER Chad Morrison It’s April. And the Winds ASSOCIATE PUBLISHER Are A-Changing. EDITORIAL Last month, I took a short trip up to Rochester, New York, during an unseasonably warm Molly J. Rogers week — and just prior to the harsh wind storm that was followed by a severe snow storm. My EDITOR timing couldn’t have been better. My host and tour guide, Buzz Maiuri of Gleason Works, joked that I brought the tepid temperatures with me from Alabama, which is certainly a Kenneth Carter ASSOCIATE EDITOR model state for unpredictable weather. During my visit to Rochester, I had the chance to tour a small job shop, Rochester Gear, where owners Tony Fedor and Scott Caccamise enthusiastically led me through rows of SALES machines — some old, some new — describing the parts they manufacture and how they use Chad Morrison their equipment. It was truly fascinating, and I want to thank Tony and Scott for spending ASSOCIATE PUBLISHER their afternoon with me. You can read more about their story in this issue’s Company Profile. I also visited Gleason headquarters in Rochester. It’s already proven to be a remarkable Dave Gomez REGIONAL SALES MANAGER year for Gleason, and it was a pleasure meeting with the kind, knowledgeable teams and enjoying a tour of the plant. I want to thank everyone who took the time to meet with me, including the friendly folks at Gleason Plastic Gears a short drive away, and a special thanks CIRCULATION to Buzz for an incredible visit to Rochester. Teresa Cooper At Gleason, I also had a chance to speak with gear-workholding expert Timothy Zenoski, MANAGER who authors an article in this issue on expanding mandrels, particularly LeCount mandrels, a household name for over a century in the workholding world. Jamie Willett ASSISTANT Hot Seat columnist Scott MacKenzie also discusses workholding as well as machining and how they can be sources of distortion prior to heat treatment. Cole Morrison We’ve covered cutting tools, too, in this issue, presenting two different and somewhat ASSISTANT non-traditional ways of producing gears. First, Dr. Massimiliano Turci discusses the whirling process for worm gears and presents a case study. And Nicklas Bylund of Sandvik Coromant ART shares some general guidelines on how to determine if power skiving is a suitable method Shane Bell for manufacturing a part as well as basic calculations for determining spindle speeds. His CREATIVE DIRECTOR tips can help in the process of selecting a tool or a machine for power skiving. Tooth Tips columnist Rick Miller shares a method that he uses for high contact-ratio Michele Hall gears, and for this issue’s Q&A, I spoke with Casandra Blassingame about AGMA edu- GRAPHIC DESIGNER cational programs. The association has an ever-increasing schedule of courses this year, and their initiatives for training and workforce development are steering the industry in CONTRIBUTING the right direction.