CyCloCutBevel GearproduCtion

GrippinG

SyStemSAdvAnces

for inCreaSed VerSatilityin molded polymer GeArsSite Safety tooth tipS hot Seat aGMa UpDate

Company profile: Artec Machine Systems Q&a: pat nugentMAhr FederAl

gearsolutions.com

DeCeMBeR 2011

see What The Future Holds

Predictive Process ControlThe NILES ZE Series has NEW features: High feed-rate grinding, Module 25 (1 NDP), High-speed measurement for full contact grinding.KAPP Technologies 2870 Wilderness Place Boulder, CO 80301 Phone: (303) 447-1130 Fax: (303) 447-1131 kapp-niles.com | kapp-usa.com info@kapp-usa.com

36Cyclocut Bevel Gear ProductionBy Dr. Hermann J. Stadtfeld

featuresCompany Profile: Artec Machine Systems

This technical paper from Gleason describes the Cyclocut process for advanced cutting, skiving, and semi-completing of bevel gears in low quantities.

26

By Russ Willcutt

Whether youre in the market for drive system design assistance or skilled maintenance and training services, this company has solutions to the challenges you face.

Gripping Systems for Increased Versatility

28

By Jesse Hayes

Comparatively simple grippers are used in an increasing number of applications where various part sizes have to be handled quickly and processed reliably. SCHUNK explains.

Advances in Molded Polymer Gears

50

By Rod Kleiss

Plastic gears can provide a hightorque, high-speed, cost-effective solution for a host of demanding applications, according to the experts at Kleiss Gears.

DECEMBER 2011

3

ResourcesMACHINES

MARKETPLACE

61 65

DepartmentsIndustry NewsTrends, data, and developments to keep you aware of whats happening with your colleagues in the gear-manufacturing industry around the country and world.

ADVERTISER INDEX

67

Terry McDonald Companies seeking qualified workers should consider members of the armed forces returning from duty, and they should provide a safe working environment.

Site Safety

DeCeMBeR 2011 | VoLUMe 9 / No. 105 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.

William Crosher In this first installment of a series, the author discusses the different types of worm gears and how useful they are in a wide variety of applications.

Tooth Tips Hot Jack Titus Seat

What we need is a nitriding process combining the speed and control of plasma, but without the degree of difficulty. According to the author, stay tuned.

Product ShowcaseNews of products, equipment, and resources from across the manufacturing spectrum that will help propel your company toward success.

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 web site, which is assumed to be cleared for release. Comments and submissions are welcome, and can be submitted to editor@gearsolutions.com.

Pat Nugent, vice president metrology systems

Q&A

Mahr Federal

8 22 23 24 56 68 17

American Gear Manufacturers Association

In this section the premier supporter of gear manufacturing in the United States and beyond shares news of the organizations activities, upcoming educational and training opportunities, technical meetings and seminars, standards development, and the actions of AGMA councils and committees.

DECEMBER 2011

5

Letter

From tHe

EDITOR

David C. CooperPuBlisher

While discussing the 150th anniversary of the Mahr Group for this months Q&A with Pat Nugent, vice president of metrology systems at Mahr Federal, he described the companys founder as an intelligent man with a healthy sense of curiosity. Seeing the growing popularity of rail travel throughout Europe, Carl Mahr designed a couple of measurement devices for that industry and the rest, as they say, is history. He recognized an opportunity, knew he had the skills to take advantage of it, and began developing products that filled a need, which is the basic formula for any successful entrepreneur. I saw that same drive on exhibit at the AGMAs recent Fall Technical Meeting in Cincinnati, where specialists from around the worldand representing companies such as Rolls-Royce, SKF, General Motors, ALD Vacuum Technologies, and the Eaton Corporation, among many othersdescribed solutions theyve developed to help gear manufacturers work with greater efficiency toward better outcomes. Its always inspiring to hear intelligent people talk about their work, and my hat is off to the AGMA for gathering together such an astute group of professionals this year. One of them was Dr. Hermann J. Stadtfeld of The Gleason Corporation, who appears in this issue discussing a process used for advanced cutting, skiving, and semi-completing of bevel gears in low quantities in Cyclocut Bevel Gear Production. Rod Kleiss of Kleiss Gears describes how plastic gears can provide a high-torque, high-speed, cost-effective solution for a host of demanding applications in Advances in Molded Polymer Gears, and Jesse Hayes of SCHUNK explains the ways in which simple grippers are being used where various part sizes have to be handled quickly and processed reliably in Gripping Systems for Increased Versatility. Jenny Blackford provides a report on the recent Gear Expo in the AGMAs special section, which also lists upcoming educational opportunities. As for our columnists, Jack Titus discusses the need for a nitriding process combining the speed and control of plasma but without the associated difficulties in his Hot Seat column. Bill Crosher begins a multi-part series on worm gears this month in his Tooth Tips column, and you are encouraged to keep returning service members in mind when filling available positionsand to provide them with a safe work environment if theyre dealing with a physical disability in Terry McDonalds Site Safety column. John B. Amendola, Sr.president of Artec Machine Systems, and another presenter at the Fall Technical Meeting this yearwas very kind in sharing his story with me, providing yet another example of someone who definitely possesses the entrepreneurial spark. As we conclude another year of reporting on this fascinating industry, Id like to thank all of you weve come to know both personally and professionally. Gear Expo is always an opportunity to catch up with old friends while making new ones, and it was great to see that everyone is doing so welleven selling machines right off the floor, in some instances. We look forward to supporting your continued growth in the years to come. All best!

Chad MorrisonassOCiaTe PuBlisher

Russ WillcuttediTOr

eDitoriAL

Chad MorrisonassOCiaTe PuBlisher

sALes

Teresa Coopermanager

CirCuLAtion

Kassie HugheyCOOrdinaTOr

Jamie WillettassisTanT

Jeremy AllenarT direCTOr

Art

Michele HallgraPhiC designer

Contributing writersWilliam P. CrOsher Jesse hayes rOd Kleiss Terry mCdOnald dr. hermann J. sTadTfeld JaCK TiTus

Vertical Logo

Published by Media solutions, inc.P. O. BOx 1987 Pelham, al 35124 (800) 366-2185 (205) 380-1580 fax

David C. Cooper

russ Willcutt, editor

PresidenT

Gear Solutions magazine editor@gearsolutions.com (800) 366-2185

Chad Morri sonViCe PresidenT OPeraTiOns

Teresa Cooper

6

gearsolutions.com

INDUSTRY NeWSGear Solutions Names Stor-Loc toolbox Winners at Gear expo 2011

New Products, Trends, Services, and Developments

Three attendees won a heavy-duty toolbox donated by Stor-Loc for Media Solutions, Inc. (MSI)publisher of Gear Solutions and Wind Systems magazinesto raffle during Gear Expo 2011 in Cincinnati, Ohio. Raffle tickets were automatically provided to those visiting the MSI booth and signing up for a free subscription to Gear Solutions magazine. We had a great time at Gear Expo this year, and wed like to congratulate our friends at the American Gear Manufacturers Association for all their hard work, according to David C. Cooper, president and CEO of MSI, adding that he also enjoyed the contribution made by the ASM Heat Treating Society. Their dedication to this industry definitely paid off in Cincinnati, and we were pleased to have the opportunity to publish the biggest issue of the magazine in its history for this show. The AGMA Fall Technical Meeting was held in conjunction with Gear Expo at the Hilton Cincinnati Netherlands Plaza Hotel. I didnt think it was possible, but this years lineup was even more impressive than the one I enjoyed during the 2010 FTM in Milwaukee, if only because there were more of them, according to Russ Willcutt, MSIs executive editor.

The range of topics was expansive, and the authors represented leading companies and academic institutions from around the world. The AGMA truly is an international organization." Winner of the first days drawing was Robert Doshi of Schafer Gear Works, (top right) and Bill Stockwell of Mitsubishi Heavy Industries America won on the second day. Robin Hines Mifsud of Hines Industries was the third winner. She is second from the left in the group photo along with (left to right) Jerrod Nowlin of C-B Gear

Companies wishing to submit materials for inclusion in Industry News should contact Editor Russ Willcutt at editor@gearsolutions.com. Releases accompanied by color images will be given first consideration.

8

gearsolutions.com

GEARED FOR SUCCESSAt AJAX Rolled Ring and Machine, our dedicated team prides itself in providing our customers with:

& Machine; Chad Morrison, vice president of MSI; Teresa Cooper, circulation manager; Jack Nowlin, president of C-B Gear & Machine; and David Cooper. Jeff Waldroup of TEAM-Industries won as a result of a drawing associated with completing our recent readers survey. To join the AGMA go to [www.agma. org]. To sign up for your free subscription to Gear Solutions visit [www.gearsolutions.com], and to Wind Systems log on to [www.windsystemsmag.com]. Learn more about Media Solutions at [www. msimktg.com].

new facility. With all the equipment in a closed loop environment, the company will deliver optimal results in class blade grinding service to ensure the quality of the spiral bevel gear production. Learn more at www.klingelnberg.com.

Metal powder Group elects officersMatthew Bulger, president and general manager of NetShape Technologies-MIM in Solon, Ohio, was elected president of the Metal Powder Industries Federation (MPIF) and Bruce Dionne, general manager of Megamet Solid Metals, Inc., in Earth City, Missouri, was elected president of the Metal Injection Molding Association (MIMA). Bulger succeeds Michael E. Lutheran of Royal Metal Powders, Inc. He joined Hawk Corporation in 2001 to run its metal injection molding (MIM) operation, which was sold in 2007 and became NetShape TechnologiesMIM. Prior to this tenure he served as a materials engineer and quality manager for FloMet. Active in the powder metallurgy (PM) industry, he has presented numerous papers at MPIF conferences, is a member of MPIFs technical board, and most recently served as president of MIMA. He has a bachelors degree in physics from Carnegie Mellon University and a masters degree in materials science from Rensselaer Polytechnic Institute. Before joining Megamet in 2005, Dionne was a regional account manager with Texas Instrument, Inc. He has a bachelors degree in geological engineering from the University of Missouri-Rolla and an MBA from Fontbonne University. Comprising six trade associations, MPIF is the umbrella trade federation representing the international metal powder producing and consuming industries. Go online to www.mpif.org.

Klingelnberg opens Blade Grinding Center in Mexico

Outstanding customer service Timely quotes Accurate documentation 2-week lead times On-time delivery Access to our extensive steel inventory

Gear up with AJAX.

C O N TA C T A N A J A X R E P R E S E N TAT I V E TO D AY.

www.ajaxring.com Toll Free: 800.727.6333 Phone: 803.684.3133

Klingelnbergs Mexico site has been moved to a new facility in Quertaro City. This investment is part of the companys long-term strategy for this important market. At the new facility Klingelnberg will soon inaugurate its new Blade Grinding Center with a Grand Opening event. The new Blade Grinding Center will be part of the claim to meet the increasing demands for this service. In the new plant at the existing location in Quertaro, Klingelnberg also offers first hand sales support, spare parts as well as professional customized service engineering and application engineering. We are now able to support to customer even better and more professionally, regarding both our machines and application engineering, says CEO Jan Klingelnberg. In terms of grinding, the customers will benefit from Klingelnbergs state-ofthe-art automated blade grinding cell B 27, the cutter head setting and checking Device CS 200 as well as the stick blade measuring device BC 10 at this

Kleiss Gears attends BioMeDeviceKleiss Gears, Inc., a world leader in polymer gear design, will be at booth 1203 at BIOMEDevice in San Jose December 6-7, 2011, to highlight the special design and production issues of plastic gears in medical devices. The companys senior design engineer, Mike Weiss, will also present an Innovation Brief entitled Precision Gearing for Medical Devices on Tuesday December 6 at 1:10 to 1:25 p.m. at on the showroom floor at booth 801.

10

gearsolutions.com

For nearly 20 years the company has designed hundreds of gears for clients around the globe, contributing substantially to meeting the growing need for truly precision gears. In the last five years Kleiss Gears medical device business has grown significantly as medical device developers recognize the companys exceptional abilities in the gearing industry and the overall lower costs. A large part of this success is attributed to the unique Shape Optimized Gear DesignTM, which results in higher contact ratios, greater strength, and smoother-acting gears. In addition, Kleiss Gears provides the full range of gearing servicesincluding design, tooling, prototyping, testing, manufacturing, and inspectionwhich enables optimum part control. Kleiss Gears has specialized equipment and experience that particularly benefits the medical device industry. Micro molding expertise enables the development and production of polymer gears in the tiniest of medical instruments. Use of nontraditional (exotic) polymers similarly allows for unique applications that were once impossible or impractical to manufacture. Finally, Kleiss Gears experience in medical quality control documentation helps customers speed through FDA filings. Learn more at www.kleissgears.com.

exceed nearly every other major industry and Original Equipment Manufacturers (OEM) specification for industrial gearbox applications. Ideal for a wide range of industrial gearbox applications, the new Mobil SHC Gear lubricants also offer valuable energy efficiency benefits. In statistically validated laboratory tests and field trials, Mobil SHC Gear fluids exhibited

energy savings of up to 3.6 percent compared with conventional oils. For many industrial businesses, gearboxes are a critical source of power transmission. That is why today, as gearbox technology continues to become more advanced, companies are increasingly seeking higher-performing synthetic lubricants, such as our new Mobil SHC Gear

exxonMobil introduces advanced industrial Gear LubricantsExxonMobil Lubricants & Petroleum Specialties announces the introduction of its new lineup of high-performance, fully-synthetic industrial gear oils, known as Mobil SHC Gear series. The latest addition to the Mobil SHC brand of highperformance synthetic lubricants, Mobil SHC Gear fluids are approved by Siemens for use in Flender gearboxes and meet or

DECEMBER 2011

11

lubricants, to protect their gearbox investment, says Mike Hawkins, global brand manager, Mobil SHC Brand, ExxonMobil Lubricants & Petroleum Specialties Company, a division of Exxon Mobil Corporation. By leveraging ExxonMobils exceptional application-specific expertise and relationships with leading OEMs, we

were able to ensure that our new Mobil SHC Gear lubricants feature the most advanced technology to help our customers reduce equipment downtime, minimize maintenance costs and maximize their productivity. Backed by extensive research and testing, Mobil SHC Gear oils are expertly

Custom Gears Latest Equipment & Technology Quality to AS9100 & ISO 9001 Superior Customer Service On-Time Delivery Best Quality + ValueSouthern Gear & Machine is a fullservice custom gear manufacturer producing some of the finest precision gears in the industry. We are uniquely equipped to produce your most demanding parts. All turning, milling, grinding, gear cutting, and gear grinding is done in-house providing us with complete control over production, quality, scheduling, and delivery of your job. With more than 50 years of experience and more than one million dollars invested in the past year alone on the most advanced equipment and technology, Southern Gear is your best source for custom precision gears, on time and on budget.

formulated to help deliver a number of performance advantages over conventional gear oil chemistries, including increased protection against conventional wear modes such as scuffing, enhanced resistance to micropitting fatigue, and extended oil life. Indeed, Mobil SHC Gear fluids offer a service life as much as six times longer than competitive mineral oil based gear lubricants. Today, Mobil SHC branded synthetic lubricants are approved for use in more than 10,000 applications and have exclusive/preferential endorsements from leading OEMs for more than 2,200 applications, spanning a wide range of industries. For more information visit www. mobilindustrial.com.

Detroit Free Press again Names Seco tools a top 100 WorkplaceFor the second year in a row, The Detroit Free Press has named Seco Tools one of the Top 100 Workplaces in the entire state of Michigan, an honor bestowed by the Troy-based companys employees. This is certainly a proud moment for our company, says Jennifer Ostroff, HR programs manager for Seco. Our employees are our most valuable assets and the key to Secos success. Therefore were committed to keeping them motivated, engaged, and inspired. Earning this top workplace distinction a second time further validates our efforts. Employee feedback from a survey administered by Workplace Dynamics served as the foundation for this Top 100 Workplace competition. The survey drew responses from thousands of employees from 215 companies. Each employee responded to a set of statements about his or her workplace, ranging from I believe this organization is going in the right direction to My pay is fair for what I do. Secos commitment to its employees includes: Ensuring leaders inspire and build trust through transparency and accessibility; Offering comprehensive training so employees achieve optimal performance;

Call us today to learn more about our cutting edge services.3685 NW 106 Street Miami, Florida 33147

Phone: (800) 248-5152 E-mail: sales@southerngear.net www.southerngear.net12southerngeargearsolutionsmay2011ad.indd 1

gearsolutions.com

4/14/11 2:33:16 PM

KEEP ASSEMBLY LINES ASSEMBLING.Because downtime is never an option, WD-40 Multi-Use Product reduces squeaks, loosens parts, and protects

tools from rust, keeping your parts and machinery running smoothly. Which is why the most trusted multipurpose industrial lubricant continues to be an essential tool for your business. Visit wd40.com to learn about a variety of WD-40 products to meet every workplace need, like the larger 16 oz. can for even more uses.

2011 WD-40 Company

Building cross-functional teams to drive future company growth; Maintaining a comprehensive benefits plan that exceeds traditional practices, and; Providing an environment where employees feel valued and rewarded. In addition to the 2011 Top Workplaces accolade, Seco recently earned its third acknowledgement from Corp! magazine for being one of Metropolitan Detroits 101 Best and Brightest Companies to Work For. The company received the honor for its innovative employee-engagement strategies, which represent best practices in human resources. Seco Tools is a leading provider of metalcutting solutions for milling, turning, holemaking, and toolholding. The company prides itself on building close relationships with customers to effectively understand and address their needs. For more information contact Lisa Seidl at (248) 528-5444 or lseidl@secotools.com. Also visit www.secotools.com/us.

announcements from Bodycote automotive North americaBodycotes automotive group includes commercial heat treat plants in Ontario, Michigan, Ohio, New York, and Mexico. Recently the plant in Rochester, New York, received its TS16949 certification and was found CQI-9 compliant. In addition the plant maintains ISO-14001, as do all Bodycote plants worldwide. Robert Scorcia has accepted the account manager position for Ontario, Canada. He joins the company from the wire and cable distribution industry where he worked closely with industries including hydro, electrical construction, elevator manufacturing, and security markets. He is a graduate from Sheridan Institute of Technology with honors in business administration and marketing. His office will be at Bodycote Newmarket, Ontario, Canada. Scorcia joins a new and successful team at Bodycote Newmarket led by General Manager Ross Hill, who joined Bodycote in August of 2011.

James Jackson has accepted the account manager position for Northern Ohio and Western Pennsylvania. James has extensive experience working with Ohio manufacturers and meeting their heat treat requirements. He is a United States Air Force Veteran and served during Desert Storm. His office will be at Bodycote Highland Heights, Ohio, near Cleveland, where he will represent Bodycotes automotive region. Bodycote is pleased to announce the opening of a new commercial nitriding plant in Southeast Michigan. Recent developments in the automotive industry created a unique opportunity for Bodycote to enter this dynamic market. Globally Bodycote is the worlds largest provider of commercial nitriding services. The company is now bringing that expertise to the automotive capital of the world. State of the art equipment has been purchased with installation scheduled for fourth quarter 2011. Production will commence the first quarter of 2012. In addi-

NEW RELEASE 03/2011

KISSsoft SOFTWAREThe Industry Benchmark for Gear Design Contact Analysis Shaft Design & Analysis Bearing Design & Analysis Lubrication Analysis Heavy Machinery, Wind, Automotive, Medical Download your free evaluation copy from www.KISSsoft.com KISSsoft USA, LLC 3719 N. Spring Grove Road Johnsburg, Illinois 60051 Phone (815) 363 8823 dan.kondritz@KISSsoft.com

RZ_kisssoft_ad_gearsolutions_quarterpage_march11.indd 1

14

gearsolutions.com

28.02.11 12:08

tion to conventional gas nitriding, various ferritic nitrocarburizing processes are offered including Bodycotes proprietary Corr-I-Dur process. The new plant will allow Bodycotes multinational customers access to nitiriding processes and technology they are already comfortable with in Europe, Asia, and South America. To learn more visit www.bodycote.com.

Gleason and heller for Strategic alliance for Gear Cutting

Gleason Corporation of Rochester, New York, and Gebr. Heller Maschinenfabrik GmbH of Nrtingen, Germany, announce the formation of a strategic alliance to serve the global gear manufacturing technology markets. Effective immediately, Gleason and Heller will cooperate in the development and sale of five-axis machining centers for gear production applications. Udo Stolz, vice president for worldwide sales and marketing at Gleason Corporation says Hellers gear cutting solutions are complementary to our own, and strengthen our ability to offer the best possible solution to our customers. Hellers innovative solutions are particularly interesting for flexible and highly productive machining of gears in small to medium batch sizes and where combined machining operations are desirable. Gleason will act as the exclusive distributor of machining centers incorporating Hellers existing gear solu-

tions, and the two companies will cooperate to further improve the capabilities of producing gears on such a platform. By leveraging Gleasons global reach and leadership in gear technology, we believe opportunities exist to expand sales of Hellers solutions. Manfred Maier, managing director of Heller, says that Heller has developed alternatives to traditional gear production processes, alternatives that do not require dedicated machines but are very productive and well suited to certain applications. We are excited about our alliance with Gleason that we believe will open our access to those applications and market segments. Gleason Corporations mission is to be The Total Gear Solutions Provider to its global customer base. Gleason is a world leader in the development, manufacture, and sale of gear production machinery and related equipment. The companys products are used by customers in automotive, truck, aircraft, agriculture, mining, wind power, construction, power tool, and marine industries, and by a diverse set of customers serving various industrial equipment markets. Gleason has manufacturing operations in Rochester, New York; Rockford, Illinois; Dayton, Ohio; Munich and Ludwigsburg, Germany; Studen, Switzerland; Bangalore; India; and Suzhou, China. It has sales and service offices throughout North and South America, Europe, and in the AsiaPacific region.

Heller is a manufacturer of four- and five-axis machining centers, flexible manufacturing systems, and machines to manufacture crankshafts and camshafts. It is headquartered in Nrtingen in the Stuttgart region of Germany. The companys products serve a number of industries including automotive manufacturers and their suppliers, machine building industry, contract manufacturers, power engineering, and tool and die manufacturing, as well as aerospace companies. Heller has production facilities around the globe including Germany, the UK, Brazil, and the United States. Additionally, Heller is represented in all major and relevant markets with sales and service bases and qualified service partners, including subsidiaries in Pune, India, as well as in Shanghai and Beijing, China. More information is available at www.gleason.com and www.heller.biz.

New Global president at Sandvik CoromantOn September 1, 2011 Klas Forsstrm took over the position as global president of Sandvik Coromant, the world-leading supplier of cutting tools, tooling solutions, services, and know-how to the metalworking industry. Forsstrm has been with the Sandvik Group for about 17 years, mostly at Sandvik Coromant. His work has included leading positions in R&D, product development, marketing, business development, and sales. Most recently he held the position as president of Sandvik Hard Materials. It is really exciting and inspiring to be back with Sandvik Coromant. I am truly impressed by what the company has achieved in recent years. As the market leader we are perceptive and forward thinking, he says. His first task as president is to manage and further develop the ambitious strategy that Sandvik Coromant has set. This includes an even stronger customer focus through local presence and global knowledge sharing. R&D is part of the very fabric that is Sandvik Coromant. We are always focused on product innovation, premium application knowledge and speed to market. Our ambition and motivation for the future is strong. I believe we will be

DECEMBER 2011

15

successful in the further development of customer oriented solutions, Klas Forsstrm explains. Short facts: Education: Klas Forsstrm holds a Master of Science in Materials Physics and an BMA from Uppsala University, Sweden. Born: 1967 in Gvle, Sweden. Family: Married to Marie Forsstrm; children: Matilda, Lovisa, Amanda and Erik. Lives: Sandviken, Sweden Interests: Family life, reading, fishing, and carpentry Sandvik Coromant is the world-leading supplier of cutting tools and tooling systems for the metalworking industry and is represented in 130 countries. Twenty-five state of the art Productivity Centers located around the world provide customers and staff with continuous training in tooling solutions and methods to increase productivity. Sandvik Coromant is part of the Tooling business area of the Sandvik Group. Learn more at www.sandvik.coromant.com/us.

oerlikon GMC 160 Gear Machining Center

diameter can be economically produced on the GMC 160 machining centers. The one machine, two process concept allows the soft cutting as well as the post heat treated hard cutting on the same machine, thereby significantly reducing upfront investment for customers. The tooling in connection with GMC 160 grants a fast, economical, and technological safe production of gears in small batches. For hard-finishing carbide or CBN-blade inserts are used which result in a high degree of surface quality. The hard cutting process (called HPG-S) delivers reproducible DIN 6 quality or better in regular production. The digital drive technology enables highest precision and repeatability. This unique solution can be utilized for the following applications: industrial gear units, marine propulsion technology, conveyors, and pulverizers. With a sturdy machine design, the flexible tooling system, a direct driven hydrostatic workpiece table, and gear technology that is completely integrated into the KIMoS based closed-loop, GMC 160 is a versatile highend solution for the demands of these markets. KIMoS data files can immediately be processed in the CNC control of the machine. Networking with the P-series measuring machines in conjunction with the appropriate hard and software enables bevel gears to be manufactured in the renowned Klingelnberg Closed Loop, i.e. exact production of Cyclo-Palloid spiral bevel gears according to nominal data including machine corrections. On top, the machine can be complemented with optionally available features. Thereby the flexible machining of straight bevel gears and cylindrical gears is also possible. Also, GMC 160 can be laid out for complete machining with turning and milling operations. Additionally available equipment such as a coaxial double spindle workhead, an automatic tool changer for the double spindle or the integrated measuring system for topography and pitch testing complete the performance range of the machine. The Oerlikon T 200 is a machine for testing the contact pattern and run of bevel gears with 90 shaft angles in the area of application of the Oerlikon GMC 160. It enables testing of gears up to 2,000 mm. CNC-controlled servo drives actuate the two linear axes as well as the gear and pinion spindle, direct measurement systems guarantee the precision of the linear axes. The testing machine is used to determine the optimum installation dimension on the basis of the contact pattern. Furthermore, a subjective evaluation of the running noise can be conducted in the speed range of the machine with programmed brake torques. Learn more at www.klingelnberg.com and www.oerlikon.com.

The spiral bevel gear machining center Oerlikon GMC 160 is optimally suited for flexible cutting of spiral bevel gears, straight bevel gears, and cylindrical gears with universal carbide blade insert tools. Gear sets up to 2,000 mm pitch

innovative Gearbox Concept analysis from RomaxRomax Technology is pleased to announce the availability of release R14.0 of the precision bearing, gearbox, and driveline simulation and analysis software, RomaxDesigner, and windcontinued on pg. 64 >

16

gearsolutions.com

American Gear Manufacturers Association

Gear Expo Takes Over Cincinnatiduring the first week of November Cincinnati was swarmed by gear industry professionals coming to attend Gear expo, the Fall Technical Meeting, and ASMs heat Treat exposition. By all accounts exhibitors were very pleased with Gear expo. A number of the machine tool builders sold equipment from the show floor, and gear manufacturers opened discussions on future sales and relationships. essentially everyone reported that they had had productive meetings with attendees, including major OeMs from a variety of sectors. Gear expo was the second-heaviest event ever held at Cincinnatis duke energy Convention Center. exhibitors brought over 750,000 pounds of equipment to the show, and exhibitors and attendees praised Cincinnati as a location. Unfortunately, our event used the entire center, with no room to expand in the future. The show was comprised of 180 exhibitors using 43,000 net square feet of the duke Center. Gear expo was co-located with the ASMs heat Treating show of 162 exhibitors in 29,500 net square feet. The two shows drew more than 4,500 attendees: 3,000 for AGMA, and 1,500 for ASM. AGMAs attendees came from 45 states in the United States and 28 countries. Both groups offered a major technical conference and several other education courses. One highlight of the educational events was AGMAs Fall Technical Meeting. Over three days, 28 speakers presented the latest results in gear research and new technical information. More than 175 gearing professionals from around the world attended the event to learn and network with some of the best experts in the industry.

during the FTM one of AGMAs most prestigious awards, the distinguished Service Award, was presented to Frank Uherek of rexnord Gear Group. Frank has been involved in AGMA since the early 1980s helping create industry standards, and even now, almost 30 years later, he is still involved in the Mill Gearing, Computer Programming, and helical Gear rating Committees, where he serves as vice chairman. AGMA Chairman Matt Mondek commented when presenting the award that, With every committee Frank has been associated; he is one of the first to step forward and accept responsibility for getting the job done. he is a tireless worker. AGMA is already planning for another great Gear expo in 2013. The 2013 show will be in Indianapolis, Indiana, September 17-19. Unfortunately, the european organizer for the eMO show will not release the dates of their shows until the current years show is underway. We recently learned that there is a conflict with eMO in 2013; this event runs from September 16-21, in conflict with Gear expo. We booked our space before the eMO dates were available, and given the physical requirements for Gear expo we have no option but to continue with the Indiana dates and location. In 2013 Gear expo will once again be co-located with ASMs heat Treat exposition and will also be in conjunction with AGMAs Fall Technical Meeting. If you werent able to attend this years Gear expo, be sure to mark your calendars now for 2013. You dont want to miss the best opportunity in the industry to see the latest technology and to network with several thousand of your gear industry peers. We look forward to seeing everyone in Indianapolis!

Jenny Blackford, director of marketing and communications American Gear Manufacturers Association (703) 684-0211 blackford@agma.org www.agma.org

JANUARY 2010

17

2012 Annual Meeting Looks to the Future

2012 will be a pivotal year, filled with the volatility of domestic politics and the international economy, which will culminate with the presidential election next November. The United States, along with the global economy, continues to be challenging and confusing, but critically important and relevant to our lives. At every turn change continues to dominate our daily life, and as much as we try to predict and plan for the future circumstances and eventualities often create a different path. The 2012 AGMA/ABMA Annual Meeting will tackle a few of the many topics that will shape our futureeconomics, politics, demographics, and more. The meeting will be held March 15-17 at the Hyatt Regency Coconut Point Resort & Spa in Bonita Springs, Florida. The keynote presenters include a few well-known names in the industry, and also experts from other fields that influence todays business community. The presentations include:

stand Out From the crowd: How to Out-Think and Out-Perform the competition Connie Podesta, Motivational Speaker, Author, Executive Coach and Industry Expert In todays world there is no such thing as business as usual. The game has changed, and the competition is closing in with new strategies. If you want to stand out and succeed in an environment where dramatic change happens at the click of a mouse, then you will have to outshine past performance, outthink old ideas, and outmaneuver anyone who says it cant be done. You will need to close the gap between where you are now and where you want to be. let your hair down in this first session and join Connie Podesta, whose message of humor and motivation will inspire you to make those personal changes that will put you on the road to success, health, and happiness.

How to Profit from the coming demographic storm Kenneth W. Gronbach, President of KGC Direct, LLC Join author and expert demographer Kenneth W. Gronbach on an exciting journey into the fascinating world of shifting demographics. Kens views are counterintuitive, global, long term, and very macro. Ken is able to forecast societal, political, and economic changes with uncanny accuracy. Ken is forecasting that manufacturing will return to our continent with a vengeance. he will show why changing demography bodes well for the United States and the Americas and why the best days for the United States are ahead, not behind us.

Calendar of Events

Whether youre looking for technical education, networking opportunities, or a way for your voice to be heard in the standards process, the AGMA has something to offer you. If you would like more information on any of the following events visit www.agma.org or send e-mail to events@agma.org.** Event open to AGMA members only. Not a member? Send e-mail to membership@agma.org.

Alexandria, VA WebEx Webinar 1 pm

Concordville, PA Orlando, FL

January

10

Industrial Enclosed Drives Committee

Marine Gearing Committee

17-18

19 19

Charting the Course Through Profound Demographic Change

24-26 24

Technical Division Executive Committee

25

Wormgear Committee Committee

12 & Materials MetallurgyCommittee WebEx

Mill Gearing Committee

Technical Division Executive Committee

25-26

High Speed Committee

Orlando, FL WebEx

Orlando, FL

18

gearsolutions.com

successful Business Growth; Five Guiding Principles Steve Barnhart, Manufacturing Specialist of IMEC (Illinois Manufacturing Extension Center) This presentation will focus on how to grow your business by entering new markets and expanding your existing markets or products. Steve will focus on the key operational issues that you need to promote success including how to evaluate your companys readiness for growth through market or product diversification. Armed with the five principles from this presentation, you will be able to assess your companys opportunity for growth; where, when, and how that should occur; and what it takes to complete it. Following this presentation a panel of our industry colleagues will present firsthand accounts of their successes and challenges with business ventures. Panelists include: rock Baty (President and CeO, NN Inc.); eduardo Garza Junco (CeO, Frisa Industries): and dennis racine (President and General Manager, Penn Machine Company). Fork in the road-Growing or slowing? Jim Meil, Vice President and Chief Economist, Eaton Corporation Will the euro currency crisis be the catalyst for catastrophe or is it a problem with a solution? Will the momentum of North American markets be maintained, or muddled up in a Washington morass? What about Chinas bubble or the trouble in Brazil? Will Obama and Boehner fumble and/or Merkel and Sarkozy stumble? Most important of all , will North American and global manufacturing be headed up or down in 2012 and beyond?

Join Jim Meil as he addresses the global economic business concerns that keep us up at night. Jim has been invited back again to offer his keen economic analysis, which is always on point and relevant. he has that unique perspective from within manufacturing and keen knowledge of what impacts our sector of the economy. Political Outlook for november, 2012 Charlie Cook, Editor and Publisher, Cook Political Report Charlie Cook is another returning favorite to the AGMA/ABMA meeting. he will have his pulse completely focused on the 2012 presidential election. By March, 2012, the front runner republican candidates will have changed several times, the battle lines will be formed, and the race will be in full swing. No one can deny the fact that the 2012 election will be truly historic. When Charlie Cook makes a pronouncement based on his analysis of the political scene in America, people who want to be in the know sit up and listen. For more than two decades he has been Washingtons most trusted and most accurate voice on all things political, whether its the outcome of a Congressional, gubernatorial, or presidential election. Cooks expertise has been featured on the ABC, CBS, Good Morning America, The Today Show, Nightline, Meet the Press, and This Week. Cook founded the Cook Political report in 1984 and became a twice-weekly columnist for roll Call, Capitol hills premier newspaper, before joining the National Journal Group in 1998. Cook has also been an election night analyst for CNN and CBS News and for every presidential election since 1994 for NBC News.

San Francisco, CA

Orlando, FL Orlando, FL

Irvine, CA

30-31

Aerospace Gearing Committee

31-1

February

1-2

Fine Pitch Committee

20-21

How to Organize and Manage a Failure Investigation

ISO/TC60/Working Group 13

22-23 23-24Cutting Tools Committee

Helical Gear Rating Committee

Gear Accuracy Committee

8-9

Powder Metallurgy Committee

21-22Ft. Myers, FL

March

AGMA/ABMA Annual Meeting

15-17

Orlando, FL Orlando, FL Ft. Myers, FL

Bonita Springs, FL

Available Year-Round

Online Workforce Education

Gain basic gear training in three courses: Fundamentals of Gearing, Gear Inspection, and Hobbing. Go to www.agma.org/events-training/detail/online-workforce-education.

JANUARY 2010

19

AGMA is gearing up for 2012 and another packed year of training opportunities for the gear industry. Whether youre involved in engineering, the shop floor, sales, or management, there are programs designed for your professional development. Most of AGMAs courses sold out in 2011, and the association anticipates strong demand for education again next year. registration is now open for all of the following programs at www.agma.org. January 24-26 Gearbox CSI: Forensic Analysis of Gear & Bearing Failures Concordville, PA March 15-17 Annual Meeting Bonita Springs, FL April 16-20 Basic Training for Gear Manufacturing Chicago, Il May 15-17 Gear Materials - Selection, Metallurgy, Heat Treatment, and Quality Control Milwaukee, WI May 16-17 Spring Marketing and Forecasting Conference Rosemont, IL June 11-13 Gear Failure Analysis Big Sky, MT June 19-21 Gearbox System design: The rest of the Storyeverything But the Gears and Bearings Clearwater Beach, FL september 17-19 Gear Failure Analysis Big Sky, MT October 1-3 International Business Conference (location to be determined) October 1-5 Basic Training for Gear Manufacturing Chicago, IL October 17-18 Fall Marketing and Forecasting Conference Rosemont, IL October 28-30 Fall Technical Meeting Dearborn, MI november 13-15 Gear Manufacturing & Inspection-Methods, Practices, Application & Interpretation for the design engineer Las Vegas, NV december 4-6 Detailed Gear Design-Beyond Simple Service Factors Alexandria, VA In addition to the in-person programs, in 2012 AGMA will also offer monthly webinars, 90-minutes in length on a variety of relevant technical and business topics. For a list of upcoming offerings and access to archived webinars visit www. agma.org.

AGMA Announces 2012 Education Schedule

AGMA LeadershipBoard of DirectorsNorbert Benik: VP of Industrial Sales, Ontario Drive & Gear, Ltd. Jim Bregi: President, Doppler Gear Company Sulaiman Jamal: Managing Director of Bevel Gears (India) Private Limited Tom Marino: President & CEO, Gear Technology Gordon New: Managing Director, Ronson Gears Pty, Ltd. Bob Phillips: Senior Vice President, Gleason Cutting Tools Corp. Bob Sakuta: President, Delta Gear Kyle Seymour: President & CEO, Xtek, Inc. Mike Smith: Vice President of Sales and Marketing, Capstan Atlantic Mike Suter: Vice President of Marketing, Emerson Industrial Automation dirk Wernecke: Global Manager, Pricing, The Timken Company

Executive CommitteeChairman: Matt Mondek President, Cotta Transmission Company, LLC Treasurer: Louis Ertel President & CEO, Overton Chicago Gear Corp. Chairman, BMEC: John Strickland VP of Marketing and Strategic Planning, Fairfield Manufacturing Co., Inc. Chairman, TDEC: Dr. Phil Terry Chief Metallurgist, Lufkin Industries Chairman Emeritus: Dave Ballard Director of Marketing & Business Development, North & South America, Siemens Industry, Inc.

Staff

Joe T. Franklin, Jr., President Charles Fischer, Vice President Technical Division Jan Potter, Vice President Membership

Contact the AGMA20

General requests: webmaster@agma.org Membership questions: membership@agma.org Gear Expo information: gearexpo@agma.org Technical/Standards information: tech@agma.org AGMA Foundation: foundation@agma.org

1001 N. Fairfax Street | Fifth Floor Alexandria, VA 22314-1587 (703) 684-0211

www.agma.org gearsolutions.com

Geared on

ValueThe target is clear when it comes to supplying the best value in gear inspection. Our mission is to offer the widest selection of reliable, productive and precise Gear Inspection Machines. We aim to be at the pinnacle of design and through our global partnering with the finest manufacturing processes, materials and components, we deliver durable, robust machines with a high degree of up time.

At Wenzel America we believe that when advanced German engineering meets American ingenuity we produce a product line with:

A huge range to inspect any size gear, A Wear-free system design, and Is built sturdy with Granite for stability, accuracy and reliability.

Striving for the Highest Precision Value inMeasurement Gear Inspection 3D Imaging

Wenzel America, Ltd. 46962 Liberty Drive Wixom, Michigan 48393 Phone: 248 295-4300 http://www.wenzelamerica.com

SITESafetyterryMcDonALDMember of the ANSI Subcommittee on Gear Safety

Companies seeking qualified workers should consider members of the armed forces who are returning from duty overseas, and they should provide a safe working environment.EvErybody knows thErEs a shortagE of qualified workers in manufacturing here in the United States. There are a lot of organizations out there doing what they can to fill in the gap, like the Society of Manufacturing Engineers Tooling U and many other training programs. Although many seek to attract high school students searching for a career path, others target veterans returning from serving our country overseas, with one example being Save Our Veterans (www. saveourveterans.org). These are people who have been handed a great deal of responsibility, many of them at a very young age, and have received training in technologies that you and I dont even know about. They deserve a chance at a good job, especially if theyve been injured, and those men and women in particular deserve a safe working environment. The reality is that many of these individuals may have special needs. They might be navigating life in a wheelchair, or learning what they can doand how they can do itwith a prosthetic limb. Some may be adjusting to varying degrees of hearing or vision loss. No matter the situation, youll need to consider their abilities in exactly the same way you would anyone elses: what skills am I looking for in this position, and does this person possess those skills or the potential to acquire them? If they do, then that should be your primary consideration. The second one should be making sure your workplace doesnt present your new hire with any unnecessary challenges. You may have noticed in recent years that public spaces such as airports, hotels, and government buildingsthe newer ones, at leastare more open than they were in years past. In some cases this is an example of whats known as Universal Design, in which the needs of people with disabilities are factored into the actual design of a structure, resulting in wider doorways, more ramped exits and entrances, and elevators that are clearly marked to provide access to upper and lower floors. What you also might notice is that this type of design is really better for everyone, with fewer tight corners and more railing around elevated platforms. Think about a ramp at the entrance to a hotel, for instance, and how that makes it easier for everybody to wheel in their luggage, and greater access inside the building allows maintenance workers to move their equipment around more easily as well. While this mostly has to do with

access, it also leads to increased safety, because you dont want someone in a wheelchair or with a cane having to take risks just to get where theyre going. And thats basically what youll need to think about at your own facility. Are the doorways wide enough for someone in a wheelchair or using other devices to get through, both in the offices and on the shop floor? Do you have parking spaces available in your lot for disabled drivers that are clearly marked both in blue and with signage, and is there adequate room on the passenger side for a ramp to drop from an accessible van? Are there graduated ramps throughout your facility for ease of entry to all areas, and are the passages between

Veterans deserve a chance at a good job, especially if theyve been injured, and those men and women in particular deserve a safe working environment.rooms smooth with no hardware mounted to the floors? Youll want to pay even more attention than usual to containing and cleaning up spills quickly, especially slick lubricants and metalworking fluids, and to make sure that manufacturing cells are contained with no moving parts unexpectedly jutting into passageways. The good news is that the manufacturing environment is generally designed to accommodate big pieces of equipment and products that need to be moved around a lot, so you should concentrate on things like making sure the height of signage, water fountains, eyewash stations, and first aid kits makes them available to everyone. Those who have risked their lives protecting our country deserve our gratitude and respect, but theyre probably more interested in moving on with their lives and getting started on a career than brushing parade confetti off their shoulders. And if theyve returned from military duty with mobility challenges we should do all we can to ease their entry back into the working world.

ABOUT THE AUTHOR:Terry McDonald is partner and manager of Repair Parts, Inc., and a member and pastchairman of the ANSI B11.11 Subcommittee on Safety Requirements for Construction, Care, and Use of Gear Cutting Equipment. Contact him at (815) 9684499, rpi@repairpartsinc.com, or [www.repairpartsinc.com].

22

gearsolutions.com

PrinciPlE: a machinEs Practical mEchanical advantage is defined as the ratio of the force expended by the machine to overcome a resistance to the force applied. The screws mechanical advantage is likely to be greater than that in any other form of machine. The worm gear is a form of screw that makes use of this inherent mechanical advantage. A screw and a worm gear have a cylindrical body with helical grooves cut into the surface. The screws mechanical advantage is the ratio of the distance traveled in one revolution to the force applied to its pitch. A worm gear uses the mechanical advantage of the ratio of plane length to height. When a screw is turned through one revolution, the screw advances the distance between successive threads. This distance is called the pitch of the screw. The inclined plane is another ancient and familiar machine and was used by the Egyptians to move stone blocks into position for the pyramids. The worm gear is also the mechanical application of the inclined plane: a plane that is rolled up in a helical form. If a gearset were assembled so the worm wheel could not rotate and the worm left free to move along its axis, depending on the direction of rotation the revolving worm would move in a forward or backward horizontal motion. The thread of the worm advances in an axial direction. When the worm is held between thrust bearings and the worm wheel is free to rotate, the revolving worm turns the worm wheel. When the worm is considered to be in a stationary fixed position, the resulting conjugate action would be identical to that of a rack and pinion. The worm wheel's pitch circle is a cylinder concentric with the axis. The worm pitch surface, on the other hand, is a plane parallel to the axis of the worm. There are two distinct types of action that take place when the worm and wheel are rotating. These actions are termed approach and recess. The approach action is a sliding action that takes place when the gear tooth slides down the side of the worm flank toward the worms central axis. This is a wearing away action that is harmful to the wheel surface. The recess action takes place when the gear tooth slides out of mesh climbing up the worm tooth away from the central axis. The friction forces are then much lower and in a positive direction. This action improves the contact, and thereby the load capacity. Whenever the worm is the driving member, the recess action is the preferred operating mode. In a full-recess action the worm pitch line coincides with the outside diameter of the gear. It is sometimes necessary

TOOTHtipSAuthor, engineer, and former director of the National Conference on Power Transmission

williamCrosher

In this first installment of a series, the author discusses the different types of worm gears and how useful they are in a wide variety of applications.to add two or three teeth to the worm gear or increase the worms lead. The approach ends and the recess action begins at the pitch line. The reversal in the direction of sliding will have the tendency to break down the oil film that can only be eliminated with all recess action. There are many advantages to the worm gear. From the earliest of times the worm gear has been widely used in many different applications because of several inherent advantages, even though it is a complicated gear to design and manufacture. Worm gears provide within one pair of gears the largest available ratio and the most compact design for gears with ratios > 10:1. Shaft axes can be at a right or acute angle. Due to the high contact ratio and material combination, worm gears have the lowest sound levels of all gear types. According to the German VDI standard 2159, the anticipated sound (noise) level for a worm gear enclosed drive is approximately 7dBa lower than a bevel-helical drive at the same input power and speed. A worm gear has more internal vibration damping than any other gear form. Due to the large area of contact and the material's properties, worm gears have the highest load bearing capacity. They are capable of sustaining high peak torques. Design ratings allow for momentary 300 percent peak loads in comparison with 200 percent for other gear forms. When it is an advantage to the application, self-locking characteristics can be utilized, within limitations. The transfer of motion is smoother than with other gear systems due to the gradual tooth engagement, and precise backlash control with provisions for minimum backlash is obtainable. Lastly, high precision worm gears can be produced with a total angular velocity deviation of less than two arc minutes. Worm gearing is considered by many to be more complex in the understanding of its design, operation, application, manufacturing, and assembly than most other types of gearing. Even so, when properly applied the worm gear is still one of the strongest, most reliable, and long-lived gears that can be selected. When the performance is below what is anticipated, the reason is usually found to have been misapplication or a misunderstanding of either efficiency, lubrication, or the thermal rating. In the application of the worm gear three areas are of special significancethreads, effective length, and tooth thicknesswhich we will consider in the next installment of this column.

ABOUT THE AUTHOR:William P Crosher is former director of the National Conference on Power . Transmission, as well as former chairman of the AGMAs Marketing Council and Enclosed Drive Committee. He was resident engineer-North America for Thyssen Gear Works, and later at Flender Graffenstaden. He is author of the book Design and Application of the Worm Gear.

DECEMBER 2011

23

jacktitus

HOTSeat

Director of process and developmental engineering, AFC-Holcroft

What we need is a nitriding process combining the speed and control of plasma, but without the degree of difficulty. According to the author, stay tuned.in thE last four wEEks my work has takEn mE to austria, Slovakia, Wiesbaden, Germany, Russia, and Cincinnati, Ohio, all having to do with heattreating gears. In my October column I stated that carburizing and induction were the two primary competing processes for case hardening gears. I didnt forget about nitriding. Gears are gas nitrided, but in significantly smaller quantities for two main reasons: the long processing time to achieve case strength, and inconsistencies in the white or compound layer especially in high alloy materials. But I believe a long-lost discovery may change the way we view nitriding as a case hardening process. Ive been very fortunate to have traveled throughout the world analyzing and developing all things heat treat, and when I return to the U.S. and contemplate the knowledge gained Im always taken by the way different countries view the heat treating process, primarily case hardening. Its not the science of metallurgy, but more how we view the equipment used to complete the process. Nitriding is a case in point. The historical record has nitriding during the 1920s being developed more or less simultaneously in Europe and the U.S. Initially the salt bath process found favor until machine components requiring surface hardening became more complex, with holes getting so small they were too difficult to clean. Eventually the gaseous process emerged solving many of the earlier problems, but lacked the processing speed of the salt alternative. Enter about 1980 Klockner of Germany who perfected the plasma process that reduced process time while enhancing white layer control. Klockner installed numerous systems in Europe and Asia. In the early eighties I was part of a team tasked with transferring the Klockner process to the U.S. About that same time the digital revolution was sweeping America with PLC development, and the PC was just starting to enter our lexicon. What an opportunity! thought our company management at the time to offer this new high tech process, but we cant keep their existing and outdated analog logic. Those and other resulting decisions affected how the plasma process was to be perceived in the U.S. for years to come. Weve got to Americanize this process because it requires too much operator

ABOUT THE AUTHOR:Jack Titus can be reached at (248) 668-4040 or jtitus@afc-holcroft.com. Go online to [www.afc-holcroft.com] or [www.ald-holcroft.com].

interaction, and that didnt square with the changing trend in heat-treat process control. Our goals were noble but we overlooked two major issues. First, we overlooked how Klockners thinking process defined and evolved the equipment. Second, as it was similarly described to me in a recent meeting, dont turn a BMW into a Chevy. But thats exactly what I wanted to do. In preparation for my effort to develop the digital process control system for the arc-counting power supply logic, I spent four weeks at Klockners commercial heat treat in Germany learning the process. It was there that the enormity of our task hit me: This so-called state of the art technology required that the German nitride operator had to cover his entire head and furnace view port in a black photographers cape to shield ambient light so that he could analyze the temperature gradient within the complex load he had constructed. Absent from ambient light 950F [510C] has color. Even though the operator had placed thermocouples in the load, the variant of part spacing and holes as the load heated could cause hot spots to occur at too many locations to electronically monitor. I thought to myself, this is Model-T Ford technology, not BMW. But this was how it was done in 1980s Germany, and they thought nothing of it. It was required for the process. Automakers and other OEMs were starting to see the benefits of outsourcing heat treat, so commercial heat treaters suddenly arose as the recipient of our sales effort. How was that going to work? Not well. Constructing a plasma nitriding load requires specific experience, knowledge, and skill, neither of which existed at commercial heat treats at the time. Add to that a brand new process control methodology and new vacuum equipment. We were doomed before the first circular vacuum vessel was fabricated. Gears are expensive to manufacture and difficult to case harden, especially when distortional tolerances must be reduced to a minimum. Gas nitriding is effective, but when tooth contact loads increase so does the case depth required, and the composition of white layer or lack of it to fight fatigue becomes critical. What we need is a nitriding process combining the speed and control of plasma, but without the degree of difficulty. A process operating under the radar in Russia that enhances ammonia, discovered decades ago, has the benefits and even more application than plasma nitriding appears to offer that solution stay tuned.

24

gearsolutions.com

What youve been waiting for.

Introducing HybridCarb a better choice from Ipsen

The new HybridCarb from Ipsen is an ultra-efficient gassing system designed to replace endothermic generators and other gassing systems. Its core strength is precision gas control. Instead of burning excess gas off, the process gas is reconditioned and reused, increasing efficiency up to 90%. HybridCarb allows for the reduction of more than 40 tons of CO2 per year the equivalent of planting 220 trees. Other benefits of HybridCarb include: Quick and easy hookup Increased carburizing efficiency Improved hardness uniformity Significantly less expensive to operate than endogenerators Consumes significantly less gas Environmentally friendly and cost efficient

For more information on HybridCarb visit www.IpsenUSA.com/HybridCarb

Visit our ASM Heat Treat 2011/Gear Expo booth #2123/2133

COMPANY profile

Artec Machine systemsWhether youre in the market for drive system design assistance or skilled maintenance and training services, this company has solutions to the challenges you face.By Russ Willcutt

26

gearsolutions.com

I

It was the early seventies, and after six years spent working as a high-speed gearing specialist for a company on the West Coast, John B. Amendola, Sr., knew that change was in the air. End users of high-speed gears were experiencing a rise in gear failures, and he wanted to work with a company that he could respect and trust. Unable to find a domestic company that struck his interest, he finally decided to approach MAAG, the machine tool manufacturer based in Switzerland. They werent really involved in much of the high-speed gearing market, but they liked being engaged in unique applications so they could apply the experience to their machine designs and keep them on the cutting edge, he says. They didnt have U.S. representation at the time, so I convinced them to let me use my connections to help them establish a foothold. I became their agent in North America, and our relationship lasted for the next 35 years. Theyre not in business anymore, but their remanufactured shaper cutters are still very popular. That relationship was also the foundation for Artec Machine Systems, which Amendola founded in North Branford, Connecticut, in 1972. The first 10 years were spent making inroads with U.S. customers, designing custom drive systems that were then manufactured by MAAG. The business began developing its reputation for tackling complicated installations, designing drive systems for demanding and highly specific applications. Construction on the companys current facility began in 1983, and it was around that time when Amendola realized it was time to establish a service department. In addition to designing gearboxes, customers were asking us to examine drive systems that were giving them trouble, doing forensics to identify and correct the problem, so we were working on all kinds of gears and gearboxes at that point, and the service center in the new building gave us room to do our work.

With each passing year the companys capabilities grew, especially those having to do with its range of technical services. In addition to rebuilding gearboxes and testing them on its API-rated test stand, Artec also offers field services including periodic maintenance inspections, condition reporting and analysis, onsite overhauls and gearbox repairsincluding bearing/rotating equipment replacementvibration analysis and diagnostics, and failure analysis. Other services include gear failure prevention, gear repair analysis, new gearbox installation and commissioning, and specification review and design upgrades. We also perform general gear training seminars with numerous clients, including the U.S. Navy, Amendola says. We provide students with the technical and practical skills theyll need to operate, service, and maintain power transmission equipment. Marine applications have become a new market for the company in recent years, especially in light of its involvement with propulsion systems for the U.S. Navy. The economic downturn of the early eighties convinced Amendola of the value of market diversification, so he has worked hard over the years to balance the companys activities among a healthy selection of industries. In addition to the military and commercial marine market Artec is also involved in high speed oil and gas transmission, heavy duty cement, power generation, ski lift drives, polymer and plastic, pharmaceuticals, and the food industries. Weve worked with customers including General Mills and Malt-O-Meal repairing their extruder drives, he says. Youd be amazed how many there are in your average food processing plant. Amendola says that he and his colleagues have worked hard to position Artec Machine Systems as the go-to company for challenging installations and applications. As an engineering design and maintenance services provider, the company has relationships in place with RENK-MAAG, Euroflex Transmissions, Kissling, and a number of high-precision loose gear manufacturers around the world. Were not interested in commodity gears or standard drive system designs, he says. There are plenty of companies out there doing a fine job with that. What were able to do is sit down with a customer who is faced with a challenging application and provide solutions, whether that involves designing a new system from scratch or examining existing drive systems to determine how they can be upgraded and enhanced. When theres an engineered product involved, were the company to call.

TO leArN MOre:Call (203) 484-2002, e-mail sales@artec-machine.com, or go online to [www.artec-machine.com].

Gripping Systems for Increased VersatilityComparatively simple grippers are used in an increasing number of applications where various part sizes have to be handled quickly and processed reliably. SCHUNK explains.By Jesse Hayes

T

THOSE IN THE AUTOMOTIVE INDUSTRY WHO WANT TO STAY FLEXIBLE IN MANUFACTURING NEED SPACE FOR GRIPPER STORAGE STATIONS AND CHANGING SYSTEMS. GRIPPER CHANGES OFTEN CAUSE UNPRODUCTIVE AUXILIARY PROCESS TIMES, WHICH REDUCE EFFICIENCY. THEREFORE THE TRENDS IN THE ONE-PIECE SERIES PRODUCTION ARE

HEADING TOWARD UNIVERSAL PLANTS AND FLEXIBLE AUTOMATED SOLUTIONS WITH MULTIFUNCTIONAL, SERVO-ELECTRIC DRIVEN GRIPPING SYSTEMS. THEY ARE VERY FLEXIBLE AND GRIP VARIOUS PARTS IN ALTERNATING SUCCESSION.

Because of the increasing variety in models,

motors and equipment can only be produced profitably if the automated solutions can be flexibly adjusted in a short time. While robots allow a high degree of flexibility during the sequences of movements, the alternating gripping of various components remains a challenge. Comparatively simple grippers are used in an increasing number of applications where various part sizes have to be handled quickly and processed reliably. In the automotive industry, where space and time are extremely critical factors, the trends go to multifunctional, servoelectrically driven gripping systems.

siMuLtAneous engineering requireD

Flexible automated solutions for automotive welding and assembly lines are far more complex. For achieving process-reliable handling, numerous factors have to be considered, such as the large variety of part sizes, varying surfaces, and different positions of possible gripping points, as well as the handling of occurring forces and vibrations. It would be ideal if the parts and plant design could be done at the same time. During the design process of car parts, for example, identical clamping and gripping points can be defined, considerably increasing the plants later degree of efficiency.

Motor AnD geAr MAnufACturing PLAy Pioneering roLeFor motor and gear manufacturing, efficient solutions already exist that allow flexible handling of various crankshafts, cylinder heads, or motor blocks. Special grippers equipped with a compensation unit, for example, can handle four different cylinder head types with a weight of up to 95 kg. For this purpose the compensation unit rests on a floating bearing and is then locked eccentrically. A stroke of 342 mm allows gripping components of different sizes. Due to the compact axes that carry the wheel rims, the gripper has optimized size/contours for confined spaces. The gripper is integrated into the existing robot control unit and does not require any additional control unit or regulator.

fLexibLe Lightweight griPPersIn addition to flexibility, the lightweight gripper now plays an increasing role for the design work of grip-

Fig. 1: A SCHUNK gripping system can easily handle a circular disk, such as a gear. DECEMBER 2011 29

system integrators, and users. A development example resulting from a cooperation between the manufacturer FFT EDAG, the robot manufacturer FANUC Robotics, and SCHUNK provide ideas on how flexible a clamping and gripping system for the vehicle manufacturing could look like. The SCHUNK LEG long-stroke electric gripper is used as a positioning unit of side skirts. The standardized lightweight gripper in the modular design weighs 8.8 kg, disposes of an enormous gripping force of 1140 N, and a variable stroke between 0 mm and 568 mm. For the use in this plant it was equipped with a servo-electric drive from the robot manufacturer. By

Fig. 2: Gripping systems make easy work of handling square objects.ping systems. Integrated into the system, the lightweight grippers save energy at the same efficiency, or achieve at the same energy consumption a

Fig. 3: Spheres are help securely in a SCHUNK gripping device.considerably higher efficiency. In both cases efficiency of the complete system increases, which is why lightweight grippers are perfect for manufacturers,

means of a plug-and-play connectivity, the gripper works like an additional robot axis and can be actuated with the same instruction set. The flexible assembly group is combined with a six-axis robot and an additional robot used as a flexible clamping device. Two

SWISS MANUFACTURERO U R P R O D U C TS... Clamping colle ts, feed fingers , Pic kup collets for Gi ldemei ster, Torn os, Index, Schtte , Wickma nn , Pittler.. Collets for Hydro ma t machines Clamping heads G ui de bus he s Parts fo r Tor nos machines Special collets on de mand UP / carbi de / small d ia me ter s

O U R N EW PR O D U C TFor more in forma tion vis it ou r web s it e: www. d t t ech n ologies. com/en /n e ws

Se ale d c olle ts

DT TECHNOLOGIES SA ZI OUEST CHAMP-COLIN 2 CH-1260 NYON - SUISSE Tel. +4122 362 8701 - Fax +4122 362 8702

www.dtte chnologie s.comSpecial collets divisi www.suppac.fron: Special collets division:

feduniec@dttechnologies.com holakovsky@dttechnologies.com

www.suppac.fr

30

gearsolutions.com

Fig. 4: Rods present no problems for these gripping systems.degrees of freedom at the gripper, five at the device, and six at the robot open up a new spectrum of possibilities.

CoMPosites Are PoPuLArNew and considerably more efficient manufacturing methods will assure that lightweight grippers in the future, which are made of composites, will take root in the automotive industry. In this example

Fig. 5: Workholding systems can be designed to handle all weights, sizes, and dimensions.SCHUNK currently presented a longstroke gripper made of carbon fiber composites with a scalable pneumatic drive. The lightweight scores in energy efficiency and in cost effectiveness. At a weight of 10 kg, the LEG-C disposes of a gripping force of up to 4,000 N and a variable stroke of up to 600 mm. If shortened finger travels are required, the stroke can be individually scaled.

DECEMBER 2011

31

HoBS for inVolute Spline din 5482

Complete line of Gear Tooling. Cutter Body Reconditioning to O.E.M. Specifications and Cutter Body Maintenance Program. Resharpening and Recoating Service, Hobs and Shapers.Blade SetS for Spiral & Hypoid gearS

neW and recOndITIOned cUTTer BOdIes for Sale.

HuB type gear SHaper Cutter

same O.e.M. Quality, Great Low Prices.

Bell type gear SHaper Cutter

Providers of world class gear tooling with first class service, quality and performance

ETCengineered tools Corporation

engineered Tools corporation 2710 West Caro rd., Caro, MI 48723 pH: (989) 673-8733 faX: (989) 673-5886 engineered Tools corporation 1307 e. Maple rd., Suite G, Troy, MI 48083 pH: (248) 619-1616 faX: (248) 619-1717

engineeredtools.com

Fig. 6: The SDH gripper hand comes in different configurations and is ideal for handling gears.This minimizes the cycle times and reduces the compressed air consumption, which makes the gripper much more efficient. For offering a continuous lightweight concept, the aluminum fingers are also executed in a lightweight design. They travel on recirculating ball bearing carriages. Via the quantity and the distance between the guiding carriages, the gripper can be exactly adjusted to the individual payload. In case of particularly high gripping forces or extremely long fingers, the distance between the carriages is enlarged. This way, even fingers with a length of more than 1,000 mm can be used. The scope-free belt drive and the synchronized fingers assure that the gripper is working precisely at variable strokes. This is ideal when large and small parts have to be alternately handled.

funCtionAL AsseMbLy grouPsAutomating plants in the automotive industry are becoming more complex and have a more compact performance, while at the same time cost pressure is continuously increasing. Customer-specific functional assembly groups from SCHUNK show how successful this balancing act can be. They combine cost and time advantages of standard components with benefits in productivity and processes of individual special solutions. The result is the highest possible level of process reliability in manufacturing and operating the plant. Moreover, the assembly groups reduce development times and increase the security in planning. The medium and long-term development of the automotive industry will lead to highly flexible manufacturing units that do not need any rigidly defined tools, devices, or gripping systems. Therefore, manufacturing one-piece series should become more economic in future with more-complex, multifaceted, sensor-equipped gripping, and handling systems will be available that will be freely programmable and easy to integrate. Concerning retooling, these all-rounders will become reusable components that can be used in new or modified processing lines repeatedly.

tALenteD griPPer hAnDIn the automotive industry there is a high need for the flexible gripping of various small components, thereby the human hand is surely the best template. The SDH-2 three-finger gripper hand from SCHUNK is structured similarly. With its seven independent degrees of freedom, it can grip and position various objects without having any setup times. The gripper hand dominates in the industrial gripping types three-finger centric, two-finger parallel and cylindrical gripping, and many other versions. A tactile sensor system safely and sensitively monitors the optimum grip and supplies information to the control unit in order to do gripping corrections if necessary. Therefore, even difficult geometries can be reliably handled, positioned, or inserted. For industrial applications, the SDH-2 is protected against dust and moisture.

ABOUT THE AUTHOR:Jesse Hayes is automation group manager at SCHUNK USA. Call (800) 772-4865 or go online to [www.us.schunk.com].

34

gearsolutions.com

g in ll e P o Pr ward r foay an Tod(Use your smartphone for quick access to our site)

ers thrust in the ls. found vesse an be large ars c ther ese and o vel ge xis, th ur be ships ical a ,o ise y vert Today er cru literall und a aneuv es aro rs can ruste that m 360 degre ding ed th s lea el dvanc tating world a Ro the al bev ically supply rd-cut spir nolog tech e. We g ha a dim oducin rn on tu rs, pr 13. e uality factur MA q manu AG take up to uture gears f the f rs o l be ginee ar wil the en go Ge ever hica p us Wher rton C at kee , Ove next ars th us e ge ing th upply d. s orwar ving f mo

d

ro mor To

w

ChiCago addison Lombard(630) 543-9570 | www.oc-gear.com | sales@oc-gear.com | 100% employee owned

Cyclocut Bevel Gear ProductionThe following technical paper from Gleason describes the Cyclocut process for advanced cutting, skiving, and semi-completing of bevel gears in low quantities.By Dr. Hermann J. Stadtfeld

L

LOW-QUANTITY BEVEL GEARSETS CAN BE MANUFACTURED WITH THE CYCLO-PALLOID

METHOD. THE CYCLO-PALLOID USES INTERLOCKING FACE HOBBING CUTTERS WITH FIVE

STARTS IN MOST CASES. FOR THE SOFT CUTTING, EACH CUTTER START INCLUDES SEPARATE OUTSIDE AND INSIDE ROUGHING AND FINISHING BLADES. FIGURE 1 SHOWS AN INTERLOCKING CYCLO-PALLOID CUTTER HEAD WHERE THE CENTER PART CARRIES AN

INSIDE ROUGHING BLADE AND AN OUTSIDE FINISHING BLADE. THE INTERLOCKING SECOND PART OF THE CUTTER CARRIES THE OUTSIDE BLADES. THE CUTTER AS SHOWN IN

FIG. 1 IS SET UP FOR THE SOFT CUTTING OPERATION. THE SAME CUTTER HEAD CAN BE

USED FOR HARD FINISHING BY SKIVING.

The finishing blades are replaced by skiving blades,

than nominal. The enlarged outside blade radii generate outside flanks that, in interaction with the nominal inside outside flanks, will lead to length crowning controlled by the amount of outside blade point diameter increase. The graphic in fig. 2 shows how the two different pitch point diameters are arranged to be approximately tangential in the center roll position at the tooth mid-face. In order to accomplish the correct position of the two interlocking cutter parts, a main (outer) spindle carries the outer cutter part, while the inner cutter part is connected to a secondary (inner) spindle. The secondary spindle is positioned at an eccentric position relative to the main spindle, such that the two pitch point circles contact each other at the calculation point in mid-face position and the offset lines of both cutter parts lie on top of each other and are perpendicular to the flank line tangent (fig. 2).

which commonly have brazed on CBN (cubical boron nitride) inserts on the cutting edges. The roughing blade slots are not used during the skiving operation. Cyclo-Palloid is a continuous indexing face hobbing method with parallel depth teeth that is based on conjugacy. This means without any flank corrections the pinion and gear flanks would contact along contact lines in every roll position. While rolling through an entire tooth mesh, the transmission ratio in case of conjugacy is perfectly constant and equal to the ratio of the pinion and gear tooth count. The motivation to use two-part interlocking cutters is based on the idea of applying a mathematically simple method to generate length crowning by combining nominal inside blade diameters with outside blade diameters that are larger

Fig. 1: Interlocking Cyclo-Palloid cutter head.

Fig. 2: Principle of length crowning by different cutter radii. DECEMBER 2011 37

Profile crowning in Cyclo-Palloid is generated with curved blade cutting edges. Both pinion and gear are strictly generated bevel gears; there is no non-generated version of Cyclo-Palloid available [1]. A hypoid offset of the pinion versus the gear is basically possible, but very seldom used in practical applications.

introDuCtion to CyCLoCutInterlocking face cutters are time consuming to build and have lower stiffness than single part cutters. Also, the provisions on the machine of a main spindle with an adjustable secondary spindle inside requires a complex design and results in reduced stiffness. Cyclocut successfully replaces the interlocking cutter with a single part cutter, which can be used on freeform Phoenix II bevel gear generators in order to produce gears with flank surfaces that match Cyclo-Palloid flanks. Length crowning is generated with single part cutters (in a completing process) by utilizing a cutter head tilt as shown in fig. 3. The untilted cutter to the left requires two cutter parts, rotating about different cutter axes (), like the case in Cyclo-Palloid. It is also possible to tilt a single part cutter about the mid-face flank line tangent and adjust the blade angle by the same amount to achieve identical

Fig. 3: Conversion of an interlocking cutter into a single part cutter.

curvature radii as in the case of different cutter axes for inside and outside blades. The mentioned blade angle adjustment also

Clarke Gear Co.57 Years of Gears One Gear at a Time!ISO 9001: 2008 EN/JISQ AS9100 REV C CERTIFIED Complete Gear Manufacture CNC Gear Hobbing CNC Gear Shaping CNC Gear Grinding CNC Inspection & Analysis CNC Machining CNC Hob Sharpening Automatic Gear Deburring Cost Control Processes

Globalpricingwith personalservice GearGrinding Specialists

www.ClarkeGear.comPhone: 888-827-GEAR or 818-768-0690 Fax: 818-767-5577 clarkegear@earthlink.net

38

gearsolutions.com

assures the correct pressure angles on both flanks. Figure 4 shows a comparison of a simulated tooth contact analysis based on the Cyclo-Palloid cutters and machine kinematics to the left and based on the single part Cyclocut cutter and machine kinematics to the right. Ease-off, tooth contact, and motion error between Cyclo-Palloid and Cyclocut show the identical characteristics. Practical trials proved that Cyclo-Palloid pinions can roll with Cyclocut gears and vice-versa without significant differences in contact patterns and rolling characteristics [2].

ing. In Cyclocut, the soft cutting prepares the root geometry for the following skiving process with a root skiving distance, a flank stock allowance, and a protuberance between flank and root fillet radius. Figure 6 shows those three geometric elements that are standard features of Cyclocut [3].

CyCLoCut skivingCyclocut skiving is a hard cutting process that utilizes coated carbide blades with a chip-forming facet that has a 20 negative side rake angle (T-Land in fig. 7). In the skiving process the blade cutting edge is required to develop a high normal force contact with the flank surface in order to penetrate into the hardened steel and form a chip. The same Pentac cutter as shown in fig. 5 for the previous soft cutting is used for the skiving only the soft cutting blades are exchanged with skiving blades. It is very advantageous to use single-part Pentac cutters instead of interlocking cutters mounted to a double spindle because of the high stiffness requirement between work and tool in the case of skiving. Cyclocut skiving is performed at surface speeds of 120 m/min and removes chip thicknesses of 0.1mm, which is equivalent to an end chip value of 0.34mm. A dry skiving as shown in fig. 8 is possible and might be the process of choice if the Cyclocut soft cutting was already done as high speed dry PowerCutting. However, wet skiving is still the

tooLs AnD Cutting ProCessThe first generation Cyclocut cutter head (shown in fig. 5 to the left) used rectangular blade sticks and was mostly applied to wet cutting with HSS (high speed steel) blades. The second generation Cyclocut cutters (fig. 5, right) utilizes five-sided Pentac slots that provide a positive seating which is beneficial for all applications of carbide blades [1]. Pentac blades eliminate basically all micromovement of the blades in the cutter head slot, which is important in order to reduce or eliminate cutting edge chipping. The machining process for soft cutting is a standard face hobbing cycle with a center plunge and double roll cycle. In order to maximize tool life, the center plunge utilizes a vector feed [2] in order to balance cutting edge wear between inside and outside blades. The preferred hard finishing after heat treatment is skiv-

DECEMBER 2011

39

standard process that delivers better tool lives than dry skiving. Skiving chips for wet cutting have a different formation and color than dry cutting. A comparison of dry and wet chips is shown in the photos of fig. 9. In any case, wet or dry, an all-around coating of the blade cutting edges is recommended in order to achieve optimum tool life results. Future developments will concentrate on a strictly dry skiving process without any tool life penalties compared to wet skiving. A typical Cyclocut gearset with a face width of 112mm and a whole depth of

25mm is shown after hard finishing by skiving in fig. 10. The tool life for the parts shown was 20 ring gears and 24 pinions, amounting to 640 gear slots and 312 pinion slots, which is a remarkable result compared to generally smaller numbers for skiving with CBN cutting edges. The reasons can be found in the carbide blade design and the higher stiffness between blades, cutter head body, supporting machine components, and work piece. Tool spacing measurement results, surface roughness, and waviness of the ring gear are shown in fig. 11. The excel-

lent spacing quality together with the low surface roughness and waviness values also confirm the optimal conditions of the Cyclocut skiving process.

tooth ContACt DeveLoPMent AnD CorreCtionsAlso for Cyclocut pinions and gears, 3D measurement of flank surfaces and flank form corrections are avail