refurbishing Wind turbine gears

AlteRnAtives
to Gear Grinding

Reducing
gear Rattle

Site Safety tooth tipS hot Seat aGMa UpDate

Company profile: JLM Systems, Ltd.
Cotta tranSMiSSion Co.

Q&a: matt mondek

gearsolutions.com

JUNe 2011

see Whats Ahead

Your Future, Our Future

Predictive Process Control
The 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-coburg.de | niles.de | kapp-usa.com kapp-asia.com | kapptec.com info@kapp-usa.com

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Refurbishing Wind Turbine Gears
By Mark Michaud, Gary J. Sroka, and Ronald E. Benson

features
Company Profile: JLM Systems, Ltd.

Isotropic superfinishing represents a value adding, low cost option for refurbishing both case carburized and nitrided gears.

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By Russ Willcutt

Developer of OILMISER technologies, this company provides clean and efficient fluid handling devices to customers found around the world.

Alternatives to Gear Grinding

40

By Sanjai Keshavan

Honing and cup wheel superfinishing can be a costeffective and higher-quality alternative to gear bore and face grinding. Nagel Precision provides the details.

Reducing Gear Rattle

By Mikel Janitz

48

The professionals at Muncie Power Products help you to addressand eliminategear noise/rattle one step at a time.

JUNE 2011

Resources
MACHINES

MARKETPLACE

61 64

Departments
Industry News
Trends, 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 Many doctors believe that carpal tunnel syndrome is caused in the workplace by making repetitive motions without stopping periodically to stretch your muscles.

Site Safety

JUNe 2011 | VoLUMe 9 / No. 99 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. 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.

William Crosher In the second installment of a three-part column, the author continues his outline of the evolution and continued development of hobs.

Tooth Tips Hot Jack Titus Seat

This month the author presents a discussion of the equipment used in the endo and low pressure carburizing processes.

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

Matt Mondek, president

Q&A

Cotta Transmission Co.

8 23 24 25 53 68

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. Letter ................................................................................................. 19 Association News ............................................................................ 20-21 Masthead ............................................................................................ 22

JUNE 2011

Letter

From tHe

EDITOR

David C. Cooper
PuBlisheR

As president of the Cotta Transmission Company, Matt Mondek is a pretty busy guy. During our conversation for this issues Q&A I asked him why, despite his many responsibilities, he still feels its important to be involved in the AGMA, to which he was recently named chairman of the board. In addition to educational opportunities and helping develop industry standards, he pointed to the value of having fellow members as a resource when presented with professional challenges. If youre concerned about the integrity of your supply chain, for example, Matt could relate how Cotta and its vendors have helped each other through tough times, thereby strengthening an already longtime and mutually beneficial relationship. Or maybe youre thinking of expanding into a new market or region, in which case other AGMA members whove done the same might be willing to share their experience, allowing you to make a better-informed decision. My favorite comment, which youll read at the conclusion of this issue, is that AGMA members are just an awesome group of people. Speaking of which, an awesome group of contributors have stepped in to fill our pages with great information this month, beginning with Refurbishing Wind Turbine Gears by Mark Michaud of REM Surface Engineering and Gary J. Sroka and Ronald E. Benson of the REM Research Group. Mikel Janitz of Muncie Power Products has written Reducing Gear Rattle, helping you to addressand hopefully eliminategear noise and rattle. Sanjai Keshavan, of the ECO Hone Division of Nagel Precision Honing, has penned Alternatives to Gear Grinding, describing how honing and cup wheel superfinishing can be a great alternative to gear bore and face grinding. Dennis Gimpertpresident of Koepfer America discusses his plans as chairman of the AGMA Foundation in the associations special section, which also includes news of upcoming educational opportunities. My thanks go out to each of these individuals for their contribution to this issue, and especially to the gear manufacturing industry at large. Bill Crosher continues his discussion of the history and evolution of hobs and hobbing in this months installment of Tooth Tips, and Jack Titus describes the equipment used in the endo and low pressure carburizing processes in his Hot Seat column. Periodic stretching is encouraged as a means of avoiding carpal tunnel syndrome in Terry McDonalds Site Safety column, and JLM Systems is our company profile. Speaking with Dick Gangnon, the companys founder and president, for this piece made me recall a conversation I once had with the dean of a school of engineering, for which I produced a magazine. Asked to sum up the characteristics of an engineer in one word, my response was precision. Her reply? While thats certainly important, I think most engineers would choose efficiency. I feel that Dick would probably agree. In closing Id like to thank all of you who stopped by our booth last month at the American Wind Energy Associations WINDPOWER 2011 Exhibition & Conference in Anaheim, California. We were there to support Gear Solutions sister publication, Wind Systems magazine, and its always a pleasure to see our friends from the gear-manufacturing world who are also involved in the wind energy market. It was a great show, and just enough to whet our appetites for the AGMAs Gear Expo in Cincinnati next November. We look forward to seeing you there!

Chad Morrison
assOCiate PuBlisheR

Russ Willcutt
editOR

eDitoriAL

Brad Whisenant
natiOnal sales manaGeR

sALes

Teresa Cooper
manaGeR

CirCuLAtion

Kassie Hughey
COORdinatOR

Jamie Willett
assistant

Jeremy Allen
aRt diReCtOR

Art

Michele Hall
GRaPhiC desiGneR

Contributing writers
ROnald e. BensOn William P. CROsheR mikel Janitz sanJai keshavan teRRy mCdOnald maRk miChaud GaRy J. sROka 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 son

viCe PResident OPeRatiOns

Teresa Cooper

gearsolutions.com

INDUSTRY NeWS

New Products, Trends, Services, and Developments

Sandvik Coromant Joins Commonwealth Center for advanced Manufacturing

Sandvik Coromant has united with the Commonwealth Center for Advanced Manufacturing (CCAM) as an originating industry member. Located in Prince George County, Virginia, the facility is specially designed to be a collaborative research center in which the member companies and academic partners can work together on R&D initiatives. CCAM will provide the industry with transformational improvements in advanced manufacturing technologies for surface engineering and manufacturing systems. Sandvik Coromant will be among some of the best industrial partners, OEMs, and suppliers from a broad range of industry sectors including aerospace, shipbuilding, nuclear, and electronics. These founding members include Canon Virginia, Inc., Chromalloy, Newport News Shipbuilding, Siemens, and Rolls-Royce. In addition, CCAMs academic members include University of Virginia, Virginia

Tech, and Virginia State University. This is an exciting venture for us, according to John Israelsson, president of Sandvik Coromant USA. This is our opportunity to shape the future of manufacturing technology by collaborating with diverse industry sectors with similar problems as well as to have access to resources for combined development work.

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.

gearsolutions.com

In the accompanying photo youll find (top row, left to right) Peter Diakun, vice president and chief technology officer, Newport News Shipbuilding; William Powers, executive vice president and CFO, Rolls-Royce North America; David Lohr, president and executive director, CCAM; Armand Lauzon, president and CEO, Chromalloy; Don Leo, Ph.D., associate dean of research and graduate studies, Virginia Tech; Robert Shenton, VP and COO, Aerojet. In the bottom row (left to right) is found Dr. John Sparks, director of engineering and technology programs, Aerojet; Dr. Charles Steger, president, Virginia Tech; Barry Johnson, senior associate dean and associate dean for research, University of Virginia; Dr. Teresa Sullivan, president, University of Virginia; Bob McDonnell, governor of Virginia; Ron Briggs, vice president of the administration group, Canon Virginia Inc.; Andreas Saar, vice president of component manufacturing solutions, Siemens PLM Software; John Israelsson, president of Sandvik Coromant USA; and Dr. Keith

Miller, president, Virginia State University. To learn more about CCAM go to [www. ccam-va.com]. Visit Sandvik Coromant at [www.sandvik.coromant.com/us].

SMes tooling U Relocates to Brick and Mortar Site

Tooling U, the leading developer of online manufacturing training, has relocated its headquarters to Tyler Village, which is one of Cleveland, Ohios, largest downtown redevelopment projects. Following the Society of Manufacturing Engineers acquisition of Tooling U last fall, a search began for a new location that allowed for continued expansion. Manufacturing is leading the recovery, and manufacturers are in greater need of training their employees, says Chad Schron, Tooling Us division manager. In order to support Tooling Us e-learning offerings, we needed to expand our brick and mortar offices. Only six miles from its previous office, Tyler Villagea former industrial complex and now a thriving, mixed-use business

complexfit the needs of the growing company. Our bread and butter is manufacturing, Schron says. We like the story that we've repurposed this space for a high-tech application. We like the unique atmosphere, and the location is still accessible for our employees. The 8,000 square-foot site has already enabled Tooling U to add additional writers, support staff, and customer success managers, which led to the launch of a new composites training curriculum. Tooling U provides training for operators in the automotive, aerospace, defense, medical, and oil and gas sectors. It also works with corporations such as General Electric, Caterpillar, and Harley Davidson as well as small and mid-sized companies and technical and community colleges. Tooling U allows operators to take classes 24/7 in a host of manufacturing topics. Classes are interactive, include both audio and video components, and provide one-on-one, synchronous training. For more information about Tooling U, e-mail info@toolingu.com or visit [toolingu.com]. Learn more about SME at [www.sme.org].

Congressman Visits overton Chicago Gear

Overton Chicago Gear (OCG) recently had the pleasure of meeting their Illinois representative. Congressman Peter Roskam, of the 6th District of Illinois serving Addison and Lombard, visited the facility on April 27, 2011. He is a member of the Ways and Means Committee and known as an advocate of ESOP companies. Roskam was interested in hearing about the strength of the industrial manufacturing sector in his district. OCG shared

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their continued success in the manufacturing of gears and gearboxes, even with the challenges of foreign competition and challenging economic conditions. Everyone at OCG thoroughly enjoyed the visit and looks forward to future visits to their facility. For more information go online to [www.oc-gear.com].

Spinelli, Jr. As a model for professional university education, Philadelphia University is focused on innovation. The careers and successes of our honorees across a range of disciplines inspire us. They are not only accomplished in their fields, but they also exemplify the universitys mission, sense of purpose, and innovative spirit. In addition to its collaboration with

Philadelphia University, MAG supports student apprenticeships with salaries and 100-percent tuition, working through local community and technical schools around the world. The company also invests aggressively in internal leadership development for promising management candidates. Founded in 1884, Philadelphia University

MaG Chairman Receives Leader of innovation Medal

MAG IAS, LLC Chairman and CEO Dr. Eng. Mo I. Meidar received a Leader of Innovation Medal from Philadelphia University at its Spirit of Innovation Gala April 30. Also honored were Jose Maria Alapont, president and CEO of Federal-Mogul Corp.; Dorothy Roberts, chairman of The Echo Design Group; and Tomio Taki, managing member of Takihyo LLC. According to Philadelphia University, the Leader of Innovation Medal recognizes creative entrepreneurs who have made significant contributions across many fields that better society and shine a light on the impact of innovation. Meidars company, MAG, is the worlds leading developer of automation technologies for producing composite structures for aerospace, automotive and wind energy. The company is also one of the largest global suppliers of machine tools and automated manufacturing systems for the durable goods industry. MAG has manufacturing and sales operations around the world. Meidar is an alumnus and trustee of the university, who has given great support both intellectually and materially. MAG recently funded the new Philadelphia University MAG Composites Institute and has donated a machining center to be used by students in manufacturing of engineering prototypes. Its an honor to be recognized with such a distinguished group of achievers as represented by this years award recipients, Meidar says. MAG enthusiastically supports the work of Philadelphia University in its development of the next generation of leaders in manufacturing, engineering and other fields. We want them to have every competitive advantage possible as they launch their careers. These friends and alumni are worldclass leaders and innovators, according to Philadelphia University President Stephen

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11

Siemens Wins order for New off-Gas Monitoring System

Siemens Industry, Inc., has received an order to provide an electric-arc-furnace (EAF) off-gas monitoring system at Steel Dynamics Roanoke Bar Divisions mini mill in Roanoke, Virginia. This order marks Siemens VAIs expansion of its patented continuous off-gas sampling and analyzing system (LOMAS) into electric-arc-furnace process optimization through continuous offgas monitoring. It is already a market leader for such technology in basic oxygen furnaces (BOF). By continuously monitoring the EAF off-gas analysis and offgas flow, and by utilizing the measured values with a SIMETAL holistic process model, this system provides instant feedback from the process and gives guidance for users to make adjustments as needed. Process inefficiencies can then be corrected by a closed-loop control for natural gas and oxygen injection through burners and lances. Consequently the technology results in reductions of overall energy, electrode, and jet-oxygen and burner-gas consumption, as well as augmented metallic yield and productivity. The LOMAS system also offers increased operational safety attributes due to its ability to quickly detect dangerous gas compositions during the melting and refining process. Greenhouse gas emission control is an added environmental benefit. The decision to install the LOMAS system was based

is a private university with 3,500 students enrolled in more than 60 undergraduate and graduate programs. Go online to [www. philau.edu]. MAG is a leading machine tool and systems company serving the durable goods industry worldwide with complete manufacturing solutions for metal cutting and composites applications. Learn more at [www.mag-ias.com].

408.723.0700

270 Hillsdale Avenue | San Jose, CA 95136 Fax: 408.723.0710 E-mail: info@ws2coating.com

www.ws2coating.com
12 gearsolutions.com

on Siemens extensive experience and success with off-gas monitoring in BOF shops, says Paul Schuler, manager or melt and cast at SDI Roanoke. This experience and their desire to bring off-gas analysis to EAF shops gave us confidence that Siemens state of the art system would allow us to monitor and control in real time our process efficiencies, which we expect to reduce costs, increase productivity, and improve safety in the melting process. Siemens Industry, Inc. (SII) is the U.S. affiliate of Siemens global Industry Sector businessthe worlds leading supplier of production, transportation, and building technology solutions. The companys integrated hardware and software technologies enable comprehensive industry-specific solutions for industrial and infrastructure providers to increase their productivity, sustainability, and profitability. Go online to [www.usa.siemens.com/ industrysolutions].

system with a new, state of the art CNC control system. New digital servomotors and drive amplifiers are properly sized to match the machines capabilities. A new operators pendant and magnetic panel typically accompanies a complete retrofit. Additionally, all existing wiring is removed from the machine and replaced with new. Konecranes has assembled some of

the most talented and experienced applications engineers in North America. They are experienced and capable of performing control retrofits using a variety of CNC & PLC controls. Konecranes has the experience to work with modern PC-based control products. Many CNC control systems will allow for reuse of some of the existing drives,

Konecranes Machine tool Service offers Retrofits

Konecranes Machine Tool Service has extensive experience integrating numerous makes and models of CNC and PLC controls to a variety of complex and conventional machines, including but not limited to gantry mills, horizontal boring mills, vertical boring mills, machining centers, grinders, turning centers. and specialty machines. In todays competitive marketplace, manufacturers are challenged to produce more precise parts in a timely manner and at an affordable rate. Many manufacturing companies are leveraging their competitive advantage via CNC controls, servomotors, and drives retrofit from their existing machinery. When properly engineered a new CNC control retrofit can increase productivity significantly, reduce the cost of energy, and improve mean time between failure rates. The group is a recognized leader in the CNC control retrofit business. Konecranes control retrofits allow customers to sustain their competitive edge in the global marketplace. After inspection a CNC control retrofit performed by Konecranes may include replacing the existing antiquated control

JUNE 2011

13

motors and wiring, thereby reducing the cost that is typical with a complete retrofit. If a machine is mechanically sound but suffers from control related failures due to age or other performance deficiencies, it may need a control-only retrofit. Konecranes will work with the customer to discuss value priced options such as upgrading controls, without the expense of replacing the existing servo motors and drives. For more information go to [www.mtsunlimited.com] or [www. konecranesamericas.com].

Mazak plans technology Center expansion

The continued upswing in business in the Midwest has spurred plans for expansion at Mazaks Midwest Headquarters and Technology Center located in Schaumburg, Illinois. The expansion represents Mazaks continuous investment in American manufacturing and coincides with other recent investments, including a new facility in Houston and production expansion at its manufacturing campus in Florence, Kentucky, to meet customer demand. The vibrant manufacturing market and our long-term commitment to customers in the Midwest convinced us to accelerate our expansion plans of our Technology Center in Illinois, says Brian Papke, president. In line with our new Southwest Headquarters and Technology Center in Houston and a new $9 million investment in our Kentucky plant, the goal of the Midwest expansion is to continuously serve our customers with solutions for improved manufacturing productivity to competitiveness of North American manufacturing. Mazak plans to move quickly on the Midwest expansion project, with a grand opening targeted for April 2012. The expanded facility will feature a new auditorium space, more room for seminars, and a spacious area for customer turnkey projects and test cuts, as well as expanded machine tool technology demonstration facilities. The company will keep customers up to date on the latest details of this and future investments via its social media outlets and Web site. Mazak Corporation is a leader in the design and manufacture of productivity-improving machine tool solutions. Committed to being a partner to customers with innovative technology, its world-class facility in Florence, Kentucky, recently initiated a $9 million manufacturing expansion. The facilitys production on demand manufacturing concept uses the latest in machine tool technologies as part of its lean strategy. Mazak maintains eight Technology Centers across North America to provide local hands-on applications, service and sales support to its customers. For more information visit [www.mazakusa.com].

LMS expands test.Lab transfer path analysis portfolio

Market leader LMS International offers the most complete portfolio of transfer path analysis (TPA) solutions available. Built on more than 30 years of continuous research and development work, LMS TPA methods are the problem-solvers of choice for noise and vibration engineers in the worlds

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leading manufacturing industries, including practically every major automotive OEM. What the market appreciates is our hands-on and comprehensive approach to transfer path analysis, says Bruno Massa, vice president of the test division at LMS International. We listen to our customers and help them implement the right techniques for the variety of noise and vibration problems they encounter. A top example in our TPA portfolio is our patented LMS Test.Lab OPAX technique. Using its wider frequency range for increased accuracy, engineers can quickly identify the root causes of noise and vibration issues faster than ever before. Plus, the depth of our portfolio means that there is a TPA solution to tackle all kind of issues from every possible angle. In complicated structures with various sub-assemblies such as cars, aircraft, or ships, vibro-acoustic phenomena at a certain location may be caused by a remote vibration source. For example, the energy from a car engine is transmitted into the passenger cavity by a number of different routes: from the engine mounts, the exhaust system connection points, and even indirectly via the drive shafts and the wheel suspension. These complex noise and vibration issues can be thoroughly examined using enhanced TPA techniques to help engineers detect root causes early in the design cycle. LMS Test.Lab provides a highly efficient solution to identify unwanted noise and vibration, trace it back to its origin, and quickly evaluate design improvements. As a systematic approach for any test-based engineering process, TPA is a valuable time-saving method that helps engineers set the right brand-critical

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noise and vibration performance targets on both the full system and component levels, Massa says. With an optimized product development cycle, engineers actually pre-design the ideal components to avert undesirable noise and vibration. On the other hand, TPA remains a popular method for troubleshooting existing vibroacoustic issues, and is rapidly spreading

from its core application area in automotive to other manufacturing industries, such as white goods, office equipment and even aviation and shipbuilding. A pioneer of transfer path analysis, LMS commercialized the first TPA product in the early 1990s under the LMS CADA-X platform. Today this know-how is baked into the market-leading LMS Test.Lab solu-

tion. Obtain more information at [www. lmsintl.com].

industry Glossary on fMa Communications Web Site

FMA Communications, Inc., announces the addition of a comprehensive industry glossary to its Web site. The glossary currently lists over 570 industry terms with an estimated expansion to over 3,200 entries. Glossary terms are also listed in the articles on the site so visitors can learn more about a particular term. The goal is for the glossary to be the largest and most comprehensive available online in the industry. The glossary is a tremendous tool for newcomers to the metal forming and fabricating industry, says Jim Gorzek, associate publisher of FMA Communications. Visitors can now find a quick definition and then look for more in-depth knowledge using thefabricator.coms robust search capabilities. The metal forming and fabricating industrys leading online resource, thefabricator. com attracts more than 120,000 unique visitors every month who are looking for articles, news, and products they need to operate and grow their businesses. Thefabricator.com adheres to the same editorial standards as all publications from FMA Communications, and content is divided into tech cells that allow visitors to zero in on their areas of interest. FMA Communications, Inc., the publishing affiliate of the Fabricators & Manufacturers Association, currently serves the metal forming and fabricating industry by publishing business-to-business magazines, e-newsletters, vendor directories, and Web sites. FMA is a professional organization with more than 2,100 members working together to improve the metal forming and fabricating industry. Founded in 1970, FMA brings metal fabricators and fabricating equipment manufacturers together through technology councils, educational programs, networking events, and the FABTECH show. FMA also has a technology affiliate, the Tube & Pipe Association Intl. (TPA), which focuses on the unique needs of companies engaged in tube and pipe producing and fabricating. Go online to [www. thefabricator.com/glossary].

At Forest City, We Always Have Gears On Our Minds...

Some folks might think a diametral pitch is a roundabout way of selling something, but we know better at Forest City Gear. Our gearheads live with the math and physics of gears on their minds, every day. Plus, they bring an unmatched knowledge of materials and CNC machine tool functionalities to the difficult task of making the world's very best gears, to exacting customer specifications, time after time after time. In our world, you see, consistency is not the hobgoblin of little minds, with all apologies to Mr. Emerson (the essayist, not the electric motor magnate). Doing something right "most" of the time simply isn't good enough at Forest City Gear, as it isn't for our customers. They demand we make it right, every time, as our products help their products perform better. As a result, their reputation rides, in part, on ours. This is a very special trust and we do our best to preserve it, all the while trying to improve the products we deliver. We do this by maintaining a machine shop that's the envy of the gear world, from the first drawing to every step in the machining process to the final inspection in our state-of-the-industry QC department and finally, to the careful product handling and packaging. For a sample of how good a gear company can be, when they maintain such "top of mind awareness" for customers, check out www.forestcitygear.com. We'll be thinking about you.

Gearheads? You Betcha.

11715 Main Street, Roscoe, IL 61073 815-623-2168

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Forest City Gear Ad4806 Island GearHeads Gear SolutionsBernard & Company 12/14/10

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a Green alternative to fluid Disposal from Quaker

Quaker Chemical offers its customers a greener alternative for the disposal of used process fluids. By recycling and reusing many of the process fluids utilized in a metalworking facility, Quaker helps its customers to lower their costs and lessen their environmental impact. When automotive production declined in the later part of 2008, many manufacturers found it necessary to decommission machines. Rather than dispose of unused process oils and lubricants, Quaker helps its customers to recycle these fluids by capturing them and either transferring them to other lines, to other facilities, or reformulating them for use in completely different processes. The result can be significant cost savings, not only in terms of waste disposal, but also as related to buying new virgin materials. For example, Quaker assisted one automotive manufacturer to recycle almost 15,000 gallons of straight oil from a machining operation and reuse within the facility, resulting in almost $100,000 of direct savings to the customer. In another instance Quaker took hydraulic fluid from a decommissioned machine and transferred it for use at another of the customers facilities, saving the customer around $20,000. Yet another example is when Quaker worked with an automotive manufacturer to convert obsolete material to meet the specification of a straight oil used for broaching, saving the customer almost $10,000. In addition to hard cost savings, there are the obvious environmental benefits to the recycling of metalworking process fluids. When a customer hires Quaker to manage the chemical specialty products in their facility, we do this through the entire life cycle of the chemical, including disposal, says Kyle Campbell, senior director of metalworking and services in North America. Its our job to educate and counsel our customers on how to get the most value from their metalworking process fluids, which sometimes includes recycle and reuse versus disposal. This may not always be the best decision for Quakers bottom line, but we are focused on making the best decision for our customers' bottom line.

Quaker Chemical Corporation is a leading global provider of process chemicals, chemical specialties, services, and technical expertise to a wide range of industries including steel, aluminum, automotive, mining, aerospace, tube and pipe, coatings, and construction materials. Quakers products, technical solutions, and chemical management services enhance customers processes, improve

product quality, and lower costs. Learn more at [www.quakerchem.com].

heat treating Sheets from precision Brand products

Precision Brand Products introduces a safer, more economical alternative to the standard tool wrap rolls, 12 x 24 type 321 heat treating sheets. The sheet design keeps handling to a minimum. The 12 x 24

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sheet size has been tested and chosen to be the optimum size to accommodate the vast majority of parts, especially those heat-treated in small bench type furnaces. Individual sheets are easy to access and fabricate, requiring one cut or less to form into a usable heat-treating envelope for the part. Less handling means less risk of being cut. The new 12 x 24 sheets are convenient-

ly packaged for easy handling and storage. The unique package allows for easy access to each individual sheet and protects from dirt and damage during storage. Excess material can be conveniently stored flat in the box. Packaged in convenient 10, 20, or 30 sheet packages, there is a quantity for every size, shop, or lab. The sheet design means less waste from excess handling and improved product performance. For

more information call (800) 535-3727 or visit [www.precisionbrand.com].

enhanced Non-Contact tube inspection Systems from RoMeR

ROMERa brand of Hexagon Metrology, Inc.announces their new line of noncontact tube inspection systems. The enhanced product line provides solutions for a wide array of tube and wire bending applications including tube inspection, bend correction to reduce scrap, reverse engineering, and fixture verification. System enhancements focus on expanded flexibility, simplicity, and ease of use to increase shop productivity. New to the system, a range of noncontact infrared probes provide operatorassisted visual notification via a laser stripe indicating the measured area. The operator can view where data points are acquired on a tube or wire during the inspection process. The probes are interchangeable with traditional ball probes without the need for re-calibration, delivering true plug and play capability. Brackets, flanges, bosses, or other geometric features can now be included in the measurement routine. Besides saving time, no recalibration also provides an additional layer of error proofing in the field. As with ROMERs legacy systems, the non-contact probing feature enables measurement of the most flexible tubes or wires from 4mm to 130mm in diameter, without risk of deflection. Zvonimir Kotnik, director of the business management group of Hexagon Metrology, sums up the new tube inspection product line. The straightforward operation of the overall system guarantees simple, flawless operation. By making the measurement process easier for the operator, we have improved efficiency, accuracy, and productivity for the entire tube shop. ROMERs tube inspection system is based on the patented ROMER Absolute Arm portable CMM. Proprietary absolute encoders are located in the arms primary axes, so the arm always knows the position of its joints. This eliminates antiquated homing procedures, so the operator can turn on the system and Continued on pg. 58 >

the premier gear manufacturer for Aerospace, defense, industrial and Automotive industries. Delta Gear products are recognized around the world for precision-quality and on-time delivery. now we have the privilege of taking the tiFCo Gage & Gear legacy of products forward with us into the future. together, our superior manufacturing capabilities, highly trained workforce and ability to manufacture highly engineered and customized products set us a part from all the other aerospace gear manufacturers. our continuous capital investment in precision CnC machinery, trained personnel, iSo9001 and aS9100 registrations, non-destructive testing and engineering solutions deliver aerospace quality at automotive prices.

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American Gear Manufacturers Association

Looking Ahead: The AGMA Foundations Future

During the 2011 AGMA/ABMA Annual Meeting, I began my three-year term as chairman of the AGMA Foundation. As we move forward I would like to share some of my thoughts on what I feel our foundation is, and where it should be going. The AGMA Foundation was originally organized in 1994 as a non-profit 501(c) (3) charity. The foundations legal structure allows companies and individuals to make fully tax-deductible contributions. The original mission of the foundation was to facilitate special financial funding of AGMAs ISO standards work.The mission was later broadened to include funding of educational and research projects in addition to the ISO and standards work. The current vision statement for our foundation is: Excellence in gearing through the advancement of gear science, standards and education, and our current mission statement is: To support the establishment of global gear standards, research to strengthen those standards and training and education to ensure their effective use. Some of the recent projects that the AGMA Foundation has supported include: Creation of a web-based version of AGMAs Detailed Gear Design program. Establishment of a scholarship program to financially assist graduate level engineering students whose programs focus on gear technology or gear research. Funding of a research program at Ohio State UniverUniver sity on Prediction of Micropitting. Funding of research at the Gear Research Institute on Gear Noise and Vibration Documentation. This summer the foundation board of trustees will meet at the AGMA headquarters in Alexandria, Virginia, to conduct a strategic planning session. Our goal will be to organize our vision and priorities in response to both our dynamic global environment and the changing desires of our donor base. Our strategic planning process will lead us to specific priorities, the building of a commitment to those priorities, and the planning for allocation of resources. In its final form the strategic plan will provide a blueprint for annual and future actions. We will ensure that our donorswho are mostly AGMA memberswill be effectively represented and served. Prior to this important strategic planning session, trustees from your AGMA Foundation board will be contacting selected individuals for a brief telephone interview. We hope to build a closer relationship with our supporters and learn your specific interests and needs. We look forward to receiving your input and suggestions. Beginning this summer, the foundation trustees and other volunteers will begin our annual fund-raising drive. They will be contacting both you and your companies to ask for financial contributions. It is important to note that these funds are used for foundation purposes, either with current or future projects, as well as building a permanent endowment fund. Also, you as a member have the opportunity to submit ideas for worthy projects as well as to participate in the scholarship program.

Dennis Gimpert chairman AGMA Foundation President, Koepfer America (703) 684-0211 www.agmafoundation.org

Detailed Gear Design Online!

AGMA has taken one of its most popular courses out of the classroom. Detailed Gear Design: Beyond Simple Service Factors is now available online in a course offering of 15 one-hour video segments. Get the same great lectures and course materials from renowned gear educator Raymond Drago at the convenience and privacy of your own personal computer. AGMA recognizes that its members need high quality advanced gear education, but the organization also recognizes that schedules, transportation costs, time out of the office, and learning styles may hamper students from attending the classroom versions of courses. In providing Web alternative learning opportunitiesdigital courses and webinarsAGMA hopes to fulfill needs of members on a more-broad basis. Detailed Gear Design: Beyond Simple Service Factors begins with a discussion of the true aim of gear design and brings into focus many of the often-conflicting considerations of designing gears to meet specific customers expectations. Cost, reliability, safety, liability, and the possible consequences of failure are just some of the factors that are covered in this course. How do we optimize a gear? How do we get the most capacity out of a gear? These questions and more are answered in this course.

Course Outline
1) Basic introduction to gear rating theory and standardized AGMA/ISO analyses methods including theoretical models for strength, durability, wear, and scoring hazard. 2) Practical considerations and limitations associated with the application of standard AGMA/ISO durability rating analyses: The theoretical surface contact stress model and its application to gear tooth contact conditions. 3) Investigation of the differences in stress states among the various surface durability failure modes including pitting, spalling, case crushing, and subcase fatigue. 4) Extended load capacity analysis techniques (beyond the AGMA/ISO standard methods) including: Subsurface shear stress analysis for the determination of optimum effective case depth and relation to subcase fatigue and case crushing. Conversion of subsurface shear stress profile into required subsurface hardness profile.

Calendar of Events
** Event open to AGMA members only. Not a member? Send e-mail to membership@agma.org.

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.

WebEx WebEx WebEx WebEx 1:00 2:30 pm EDT

June

Mill Gearing Committee Meeting

Helical Gear Rating Committee Meeting

9Energy Efficiency 14

14

Enclosed Drives for Industrial Applications Committee Meeting

15

AGMA Webinar SeriesConditions for Cutting Tools

Cutting Tools Committee Meeting

7-8

Wind Turbine Committee Meeting

14-15

Plastics Gearing Committee Meeting

21-22

Helical Enclosed Drives High Speed Units Committee Meeting

Alexandria, VA

WebEx Chicago, IL Hartford, CT

gearsolutions.com

5) Consideration of friction in the calculation of surface compressive stresses: The relation between pure Hertz-type compressive stress and pitting. The relationship between spalling and the occurrence of a combined tension and compression state at the tooth surface due to mesh friction effects. 6) Practical considerations and limitations associated with the application of standard AGMA/ISO strength rating analyses. 7) The theoretical strength stress model and its application to gear tooth bending stress evaluation: Correspondence between calculated stress numbers and actual measured tooth root stresses. 8) The effect of gear blank rim thickness on the tooth root stress state: Rim bending participation. The rim thickness factor, development and limitations. 9) Discussion of differences between fatigue, time dependent, and time independent failure modes as related to gear tooth design: Durability and strength. Wear. Scoring. 10) Wear evaluation by the application of elastohydrodynamic analyses Basis of the analysis development. Probabilistic nature of wear evaluation. Time dependent, non-fatigue nature of wear progression. Self propagating mechanism.

11) Scoring Hazard evaluation by the application of Bloks Critical Temperature theory: Basis of the analysis development. Probabilistic nature of the problem. Time independent nature of failures. 12) Optimization of gear tooth detail design parameters including: Considerations for minimum roll angles. Effect of and design for specific sliding (slip ratio) and entraining velocity. Stress balanced or life balanced gear pinion and gear relative design. Influence of geometric characteristics such as tooth top land, tooth thickness, etc., on optimized tooth design. 13) Considerations of fillet geometry in the avoidance of fillet interference and excessive stress concentrations due to adverse fillet geometry. Computer generated animated graphics will be used for examining mesh action and tooth interaction. Each section discussion will be followed by a brief question and answer period. The registration fee will include all meeting materials, scheduled meal functions, and an opening evening networking reception. A certificate will be awarded to each attendee.Jan Alfieri, AGMA Education Manager

Providence, RI WebEx WebEx Alexandria, VA

23 Committee Meeting 27-29

Gear Failure Analysis Seminar

Fine Pitch

July

12

Spline Committee Meeting

19

Helical Enclosed Drives Marine Units Committee Meeting

26-27

Sound & Vibration Committee Meeting

14

Helical Gear Rating Committee Meeting

20-21

Powder Metallurgy Committee Meeting

WebEx Big Sky, MT

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

21

AGMA Announces Fall Education Schedule

Gear Failure Analysis Seminar
September 19-21, 2011 Big Sky Resort, Big Sky, MT

AGMA is looking forward to an education-packed fall season. Registration is now open for the following events at [www.agma.org].

Gear Manufacturing & Inspection: Methods, Practices, Application & Interpretation for the Design Engineer
October 18-20, 2011 Cleveland, OH

Avoid gear failure and save thousands of dollars in repair costs by knowing what causes gear failure and how to prevent it from occuroccur ring. This course is a perennial sellout and is limited to 30 students, so register soon. Students will examine the various types of gear failure such as macropitting, micropitting, scuffing, tooth wear, and breakage. Possible causes of these failures will be presented, along with some suggested ways to avoid them.

Basic Training for Gear Manufacturing

October 3-7, 2011 Chicago, IL

In this seminar students gain a broad understanding of the methods used to manufacture and inspect gears, and more. The course takes the process one step further, teaching how the resultant inforinfor mation can be applied and interpreted in the design process. This seminar aims to narrow and possibly close the information gap by providing gear design engineers with a good foundation in both manufacturing and inspections processes and procedures.

Gearbox System Design: The Rest of the StoryEveryStoryEvery thing but the Gears and Bearings!
December 6-8, 2011 Clearwater, FL

The AGMA Training School for Gear Manufacturing will enable students to become more knowledgeable and productive. The Basic Course teaches participants to set up machines for maximum efficiency, to inspect gears accurately, and to understand basic gearing. Although the course is designed primarily for newer employees with at least six months experience in setup or machine operation, it has proved beneficial to quality control managers, sales representatives, management, and executives.

This program addresses what gear engineer can do to optimize the gearbox system, from the housings to the lubrication and much more. The seminar starts with the basics: history of design, the environment in which the gearbox must live and the loading to which the system will be subjected in service. Loading includes starting/ stopping, continuous, reversing, cyclic and possible errant loads conditions.

AGMA Leadership
Board of Directors
Norbert 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 Committee

Chairman: 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 AGMA

www.agma.org gearsolutions.com

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

500 Montgomery Street, Suite 350 Alexandria, VA 22314-1581 (703) 684-0211

Weve all seen people Wearing those braces on their wrists that extend from the knuckles to midway up the forearm, and most of us know someone whos had to wear oneif we havent had to, ourselves. While some might be the result of a tennis injury or something along those lines, most often theyre being used to treat something known as carpal tunnel syndrome, or CTS. Although doctors have different theories, most agree that CTS is caused by repetitive motion such as typing on a keyboard for many hours each day or performing the same physical motion in the workplace. Steady pounding and constant vibration have also been cited as possible causes. What happens is that the median nerve passes through the carpal tunnel in your wrist,

SITESafety
terryMcDonALD
Member of the ANSI Subcommittee on Gear Safety

Many doctors believe that carpal tunnel syndrome is caused in the workplace by making repetitive motions without stopping periodically to stretch your muscles.

Carpal tunnel syndrome gets more painful as it progresses, and you can even experience weakness in your hands, which can really cause problems for people who work in manufacturing.

and when the surrounding tissue begins to swell it presses against the nerve, and with no way to relieve the pressure within the carpal tunnel you begin to experience pain and numbness in your hands. And, yes, it seems to be another one of those complaints that you need to protect yourself against even before it starts hurting, which can be difficult to do without that painful reminder. Many doctors think the damage is cumulative, so it just seems to get worse once the aching begins, and wrist braces cant do anything about the damage thats already been done. They mostly serve to immobilize the wristand to remind you to take a break every now and then. you want to keep your hands in motion. I sometimes think that there seems to be more people getting migraine headaches these days, and ABOuT THE AuTHOr: Ive often wondered if it doesnt have something to Terry McDonald is partner and manager of Repair Parts, Inc., and a member and do with all the time we spend staring at a computer pastchairman of the ANSI B11.11 Subcommittee on Safety Requirements for screen, sometimes only a foot or two away. They Construction, Care, and Use of Gear Cutting Equipment. Contact him at (815) say that if you do that type of work you should take 9684499, rpi@repairpartsinc.com, or [www.repairpartsinc.com]. a break once an hour or so and stare off into the

distance so that your eyes can adjust. Thats good advice for people who perform a repetitive motion with their wrist all day, too, like working on an assembly line or some type of manually operated machine like a drill press. It can be hard to find the time to do it when youve got a schedule to keep, but its important to stop what youre doing periodically and stretch your wrist into positions that are different from those youre doing in your work. By gently flexing your wrist backwards and forwards, then to the sides, and repeating that motion, you should feel your muscles begin to limber up, and hopefully they wont start getting stiff as quickly once youve resumed your work. Like Ive said, though, its a good idea to go ahead and get in the habit of doing this before you start experiencing pain. Its called being proactive, and thats always a good idea. In case youve been feeling pain in your wrist and wondered what it was, the symptoms involve tingling and numbness at the base of your fingers and in your wrist in the early stages. It gets more painful as it progresses, and you can even experience weakness in your hands and a loss of grip strength, which can really cause problems for people who work in manufacturing. While machines are more automated than ever, there is still plenty that has to be done by hand, so losing the ability to grip tools and controls firmly is something you definitely want to avoid. If youre involved in this type of work and are experiencing these feelings in your hands and wrists, you need to pay your doctor a visit where they can diagnose CTS fairly easily. If you do have it treatments can involve everything from steroid injections, to occupational therapy, to the immobilizing wrist braces Ive already mentioned, to a procedure called carpal tunnel release surgery. The good news about the surgery is that it has a 90-percent success rate, with people able to go back to their jobs after a short period of recuperation. The bad news is that its still surgery. Like Ive said, doctors arent in agreement about what causes carpal tunnel syndrome. Some think its genetic, while others feel that its a result of repetitive motion. Whatever the cause, statistics show that one in 10 people will develop CTS at some point, and those who do will end up shelling out about $30,000 for treatments and surgery during their lifetimes. So stop and stretch periodically if

JUNE 2011

23

TOOTHtipS
williamCrosher
Author, engineer, and former director of the National Conference on Power Transmission

In the second installment of a three-part column, the author continues his outline of the evolution and continued development of hobs.

An alternate to the use of a hob is a fly tool, and they are frequently used in the cutting of a worm wheel with tangential feed. This method has none of the irregular flank contours that are present when a hob is used. The simple tool is reasonably easy to make, and it reduces the tooling cost when manufacturing small quantities of high-precision special gear forms. Hobbing is five times faster than fly cutting, but hobs are much more expensive.

TangenTial feed hobs are in Three basic designs: pancake, multiple-spiral cylindrical, and pineapple. The former are low in cost with a narrow face and a minimum of cutting edges, wear rapidly, and have longer cutting times. Globoidal worms can be produced on a standard hobber by reversing the location of the cutter or bladed cutter assembly with that of the gear blank. The cutter is fed radially into the blank to produce the form. To obtain maximum benefit after the hob is fed to the proper depth, the gear blank must be rotationally advanced and retarded for a trimming cut on each flank. The mating gear is for all practical purposes impossible to cut by conventional methods.

ACCurACy grADes
Hobs are available in five accuracy grades: Class AA-Ultra Precision Ground; A-Precision Ground; B-Commercial Ground; C-Accurate Unground and; D-Commercial Unground. The tolerances for Class AA were established by the Barber-Colman Company, and the others by the Metal Cutting Tool Institute. The hob accuracy has a direct relationship with the quality of the gear being produced. The hobs cutting edges maintain the correct pressure angle and lie along a helix with the established lead. A Class AA will be capable of producing an AGMA A5 (Q12) gear, and if Class B an AGMA A7 (Q10) gear when the hob has an adequate number of gashes, was properly mounted, and their tolerances maintained after sharpening. Hobs are form-relieved cutters. They are sharpened by grinding the faces of the hobs teeth to the bottom of the flute. Errors frequently arise after the hob has been sharpened. A consistent amount of metal must be removed from each succeeding row of teeth. The errors are usually in profile and lead, as the hob profile can be changed from its true position by exposing the cutting edge to a different plane. The hob accuracy can be affected during the sharpening process by errors in the rake angle, flute lead, and indexing. All standard hobs are designed with a generating profile (basic rack) that defines the pressure angle, the fillet radius, addendum and dedendum, and modifications to assist following operations such as shaving and grinding, etc. It is essential to inspect the hob after sharpening.

Hobs are form-relieved cutters, sharpened by grinding the faces of the hobs teeth to the bottom of the flute, and errors frequently arise after the hob has been sharpenedusually in the profile and lead.
Cutting teeth
There are two popular methods used to cut the teeth: generating, and by using a formed cutter. Two designs of cutter are used are either a rotary type or a planer type tool. Using the formed rotary cutter, one tooth space at a time is cut, leaving a gap the same shape as the cutter. The most complex and costly tools used for metal cutting are those that are used for cutting teeth, particularly form cutters. Coatings are successfully used to improve tooling economics by increasing the time between sharpenings, and by keeping most of the heat away from the substrate material. Coatings for shaper cutters and hobs have been in widespread use since 1980. The latest hob technology is to use coated carbides or high-speed steels. The thin ultra-hard film increases the tools abrasion resistance and reduces tool-part adhesion. The first coating to find general use was the gold colored titanium nitride (TiN). An estimated increase in tool life of 200-300 percent is considered conservative. The better the surface before the coating is applied, the better the overall results.

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.

24

gearsolutions.com

ive explained in previous columns a few basic tenants of endo and low pressure carburizing processes, so perhaps a discussion of the equipment used in each is in order. Atmosphere carburizing with endothermic gas, in-situ gas such as LPG (liquefied petroleum gas and air), and nitrogen-methanol utilize refractory lined furnaces typically insulated with ceramic fiber or insulating fire brick (IFB). These furnaces fall under the broad category of hot walled furnaces; devices that are warm or hot to the touch. Ninety-five percent of all heat treating is performed in this type of equipment. Vacuum furnaces, cold wall vessels with water jackets, require a chamber capable of being evacuated to pressures approximating 0.0001 of an atmosphere. Your local weather forecast in the U.S. likely reports barometric pressure in inches or millimeters of mercury. This means atmospheric pressure at sea level can be stated as 14.7 psi, 30 inches of mercury, and 760 mm of mercury. A developing low pressure weather system may be reported as 29 inches or 735 mm of mercury. In metric terms pressure is referenced in bar, one bar = atmospheric pressure and for accuracy 1013 millibar equal one atmosphere. For LPC to work properly a vacuum vessel starting out at atmospheric pressure, 1013 millibar must have the air removed by a vacuum pump so that only 0.1013 millibar remain, (99.9999 percent) of the air is removed. In scientific terms 1 x 10-4 millibar. Atmospheric pressure on the moons surface is 1 x 10-11 millibar. Dont confuse barometric pressure with gravity; some think removing that much air will allow parts to float around within the vacuum vessel. Gravity is the force that keeps our feet on the ground; atmospheric pressure allows us to breathe. As indicated above, IFB insulated furnaces are used in endo carburizing. However, vacuum furnaces employing LPC are primarily insulated with only two or three inches of rigid graphite board or graphite felt. Since oxygen has been removed graphite (carbon) wont burn as it would in air, and since the pressure is very low, heat transfer to the steel vessel wall is low as well but the cold side of the graphite insulation is still very hot generally about 400F to 700F. Thus, almost all vacuum furnaces have water-cooled casings. Commercial vacuum furnaces began as single chamber devices in the late 1950s with a 0.032 inch thick molybdenum metal hot face and a few inches of ceramic fiber insulation, since ceramic fiber was in use in atmosphere furnaces and

HOTSeat
Director of process and developmental engineering, AFC-Holcroft

jacktitus

In this installment of his column the author presents a discussion of the equipment used in the endo and low pressure carburizing processes.

graphite insulation was not yet invented. Heating elements now made from graphite were in 1950 made from tungsten or molybdenum rod. Vacuum furnaces continued to evolve retaining a gap between the insulated hot zone and the water-cooled casing. This design attribute subsequently becomes a maintenance issue in LPC. Then, in about the mid-seventies, in an effort to duplicate the integral quench batch atmosphere furnace, multi-chamber vacuum furnaces began to appear. Initially vacuum furnaces were primarily used for annealing and hardening small high-speed tools such as drill bits. One may wonder why, with atmosphere furnaces requiring 13 inches of insulation, a vacuum furnace has only a few inches when they can operate a much higher temperature. The reasons, I speculate, are twofold:   he very first R&D vacuum systems consisted of a tabletop mounted bell T jar and vacuum pump located beneath, and when someone had the idea of adding heat the most practical solution was a heated box inside of the jar and the space between the jar and box for wiring;  s vacuum furnaces evolved and cooling was added to single chamber A furnaces in an effort to force cool the parts as fast as possible, it became necessary to reduce the heat stored in the insulation; solutionreduce the thickness. Since heat transfer in vacuum is significantly less than at one atmosphere it worked, to a degree. No pun intended. In the U.S., except for a few locations atmosphere furnaces are heated with natural gas fired radiant U tubes. Vacuum furnaces designed for traditional hardening and LPC due to the hot zone/inner chamber construction and because of higher operating temperature most often have resistance heated graphite elements. Vacuum, having effectively very few gas molecules, has very little resistance to high voltage jumping across a small space resulting in an arc, therefore the (secondary) electrical power connected to the heating elements must be limited to 80 volts AC, 60 Hz. LPC having acetylene gas thus the potential for soot (carbon) that is electrically conductive must limit the power to 24 volts AC. Next month, more on furnace construction and types of heat treat equipment.

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].

JUNE 2011

25

COMPANY PROF ILE

JLM Systems, Ltd.

Developer of oiLMiSeR technologies, this company provides clean and efficient fluid handling devices to customers found around the world.
By Russ Willcutt

26

gearsolutions.com

Whats the recipe for creating an innovator? In the case of Dick Gangnon you take one part engineer, with their dedica tion to creating efficient systems; a smidgeon of the inven tor, whos always dreaming up better ways of doing things; and a dash of the entrepreneur, who is willing to take risks and harness new technologies. My background is in industrial engineering, so efficiency is what its all about, says Gangnon, who is president of JLM Systems and developer of OILMISER technologies. I began my career back in the mid-sixties in the wire rope business, where I started learning about lubricants, and then I went into hydraulics as a technical sales representa tive for several companies. In those days, when the price of hydraulic fluid was about 27 cents a gallon, people werent concerned about conserving it. The system reservoirs were huge, and when it was time to change the fluid youd just discard it. That changed in the seventies, when the price rose to more than a dollar a gallon and certain environmental regulations were introduced, and suddenly everyone wanted smaller reservoirs on their hydraulic systems for less fluid usage. In smaller quantities, the contaminants common in fluids at that time as a result of improper handling became concentrated, slashing equipment uptime. People werent careful with their lubricants back then, Gangnon recalls. It would arrive in 55 gallon drums, and they would simply pour it into whatever bucket was available to transfer it to the machines. And when youre talking about sawmills or mining operations, its a very dirty environment, so the oil and the receptacles that held it were just filthy. It was readily apparent to me that this contamination was responsible for the vast majority of equipment breakdown and downtime they were experiencing, so I decided to do something about it. His solution was the OILMISER FILLorDRAIN, which effectively closed the loop on airborne contamination between the drum and reservoir. He established JLM Systems to manufacture the device, which he sold through the companies he represented as an outside salesman. The success of the FILLorDRAIN motivated him to consider other challenges he could help his customers overcome, and he continued launching new products as a sideline venture. He also continued broadening his experience, eventually becoming director of hydraulic operations for a large industrial supplier. Then a technology made its appearance that changed everything for him. Its called the Internet, Gangnon says with a laugh. As it grew in popularity I realized it represented a way for me to eliminate the middlemanwholesale industrial suppliers, in my case, who werent that interested in taking on new linesand sell directly to the end user. So thats what I decided to do.

After taking classes to learn about the Internet and Web-site design, Gangnon began devoting all his energy to JLM Systems in the late nineties, introducing the products hed been dreaming up in quick succession. In 2000 he launched a modified FILLorDRAIN for oil sampling, then an offline filtration kit featuring a kidney-loop design in 2003 and a color-coded filtration system the following year. The OILMISER Vapor Guard appeared in 2004, and soon sample tubes, reservoir aspirators, and sampling plugs and valves came on the scene. Today the companys Web site features a wide selection of devices, supplies, and accessories that can be purchased directly or through a network of approved resellers. Just as the advent of the Internet enabled the launch of his company, it continues to play a major role in how it operates. In addition to speaking on the subject to various companies that bring him in to educate to their employees, Gangnon communicates with end-users all around the world who send him photos of their machines and systems so that he can suggest OILMISER devices that will meet their requirements. At this point all I need to see is a picture of their setup, ask a couple of questions, and I can tell them exactly what they need, he says, and Ill either sell it to them directly or to their preferred local vendor. Gangnon has seen many changes over the years, including the elevation of a job once referred to simply as maintenance to a highly specialized field made up of reliability engineers and technicians, with their own set of professional certifications. As for what motivates him today, he says his goal remains unchanged. When you encounter inefficiency, its likely to stay that way until somebody does something about it, he says. And when it comes to hydraulic systems, that somebody is me!

TO LEArN MOrE:
Call (888) 736-8645 or (604) 521-3248, e-mail info@oilmiser.com, or visit online at [www.oilmiser.com].

Refurbishing Wind Turbine Gears

Isotropic superfinishing represents a value adding, low cost option for refurbishing both case carburized and nitrided gears.
By Mark Michaud, Gary J. Sroka, and Ronald E. Benson

M
Wear is greatest on the input stage, especially on the sun pinion gear. Historically, grinding is utilized to refurbish these damaged gears. There including but not limited to high capital investment and the extraordinary amount of time and skill involved in are numerous drawbacks, however, the grinding process. Moreover, nitrided gears cannot be ground and must be scrapped. However, chemically

MULTI-MEGAWATT WIND TURBINE GEARBOXES OPERATE UNDER DEMANDING ENVIRONMENTAL CONDITIONS INCLUDING CONSIDERABLE VARIATION IN TEMPERATURE, WIND SPEED, AND AIR QUALITY. IT IS NOT QUALITY A FEW YEARS. THESE GEARBOXES EXPERIENCE SEVERAL TYPES OF REPAIRABLE DAMAGE INCLUDING

UNCOMMON FOR GEARBOXES RATED FOR A MAINTENANCE FREE 20-YEAR LIFESPAN TO FAIL AFTER ONLY 20MICROPITTING OR GRAY STAINING, ABRASIVE WEAR, FOREIGN OBJECT DEBRIS (FOD) DAMAGE, SURFACE

CORROSION, AND FRETTING CORROSION.

accelerated vibratory finishing, or isotropic superfinishing (ISF), represents a value adding, low-cost option for refurbishing both case carburized and nitrided gears. Isotropic superfinishing removes light to moderate gear flank surface damage. The result is a surface with a non-directional pattern with a roughness of approximately 0.08 mm or less. Moreover, evidence suggests that isotropic superfinishing imparts a finish that increases gear durability and service life in the field. A case study on a sun pinion gear is presented.

introDuCtion
Typical multiple megawatt (MW) gearboxes, 1.5 MW and higher, are designed to operate for 20 years without requiring major maintenance to the drive train. However, many owners

Fig. 1: Micropitting or gray staining on gear flanks (a), heavy abrasive wear on gear flank and a SEM image of trail left by an abrading particle (b) [4], a foreign object debris (FOD) damage (c), corrosion looking down on top land (d) [4], and fretting corrosion (e). JUNE 2011 29
b d a

are experiencing gearbox failures after only a few years of service. Gearbox repairs may cost $360,000 (USD) or more for a complete replacement by 2009 estimates [1]. Gears fail for several reasons. Wind turbine gears operate under extreme environmental conditions including highly variable temperature, wind speeds, and air quality. These conditions cause variable high loading and torque. During periods of low or no wind, the loading on slowly moving or stationary gears is exacerbated. Moreover, moisture can contaminate the lubricant and condense on the gear surfaces forming sludge, corrosion and micropitting. Finally, dust and other foreign debris in the air can contaminate the lubricant during maintenance, leading to abrasive wear. Fortunately condition monitoring systems allow gearbox prob-

Fig. 3: Ground surface (top) vs. an isotropic superfinish surface (bottom).

Fig. 2: The superfinishing process.

Fig. 4: A crack on a used gear near the addendum of the tooth was revealed only after superfinishing.

Fig. 5: Graphite tape lifts from damaged gear surface before (top) and after (bottom) superfinishing refurbishment. 30 gearsolutions.com

lems to be discovered before serious gear damage occurs [2, 3].

cesshenceforward referred to as superfinishingis an alternative time and cost efficient method of gear refurbishment. The process utilizes conventional vibratory finishing equipment and high density, nonabrasive finishing media to produce isotropic surface finishes with a final surface roughness (Ra) below 0.10 mm. The superfinishing process is easily understood by referring to fig. 2. At the start of the superfinishing process shown in step 1 of fig. 2, the original metal surface reacts a first time with the active chemistry, forming the first conversion coating (step 2) [8]. The vibratory machine and nonabrasive media produce an effective rubbing motion on the surface of the gear (step 3). This exposes the peak asperities of the metal surfaces to a second reaction (step 4), reforming the complete conversion coating. The process of conversion coating reformation and removal (step 5) is continued through many successive cycles, thus planarizing

the original rough machined or damaged surface. The final required surface finish governs the total number of cycles. This planarizing process is continued until the gears are smoothed to the required surface finish quality. Once the required surface finish quality is achieved, the active chemistry from the smoothing stage of the superfinishing process is drained away and a neutral, burnishing soap is introduced into the vibratory machine. The burnish removes all remaining conversion coating (step 6) from the surface of the gear, producing a mirrorlike appearance while imparting a mild rust preventive to the surface. The gear is ready for unloading and the superfinishing process is complete. Figure 3 shows a comparison of a ground gear surface versus a superfinished gear surface. The initial selection of the proper media shape, size, and mixture is a significant part of the art to successfully superfinishing gears. Media is specifically cho-

bACkgrounD
As mentioned, wind turbine gears experience several types of repairable damage including micropitting or gray staining, abrasive wear, foreign object damage (FOD), surface corrosion, and fretting corrosion. An example of each is depicted in fig. 1 [4, 5]. There are three main approaches to repairing gear damage: refurbishment by regrinding, refurbishment by surface finishing, or replacement with a new gear. The refurbishment process is a combination of reclamation and reconditioning of a used gear or bearing [6]. New gearing is expensive, which makes surface finishing and regrinding the preferred low-cost alternatives. Regrinding is necessary when lead and profile corrections are required on the working surfaces of the gear teeth [7]. The Isotropic Superfinish, or ISF pro-

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sen based on the following criteria: root diameter, diametral pitch, gear size, gear mass, and alloy. Once the media is chosen, the superfinishing process repeatedly finishes gears identically. The media is nonabrasive, and therefore has a very low attrition rate. The size, shape, and density of the media remain stable over thousands of hours of vibratory machine

operation. The superfinishing process possesses several ideal features.  uperfinishingremovesmetaluniformly S from every tooth of the gear with the ability to control total stock removal down to below 2.50 mm;  hereisnodiscolorationortemperburn, T a risk that is associated with grinding;  uperfinishingdoesnotdestroyresidual S compressive stress surface layers [9].

Residual compressive stress is imparted on the surface during case hardening. Compressive stress slows the rate of surface wear and inhibits corrosion [10]. Hence, the superfinished gear exhibits a superior surface versus used gears that are refurbished by grinding;  heprocessworksonnitridedaswellas T case carburized surfaces;  he superfinishing process is an ideal T technique for improving the inspection

c Fig. 6: Surface trace of a new ground low-speed stage pinion before superfinishing: 2282 (a), of a used low-speed stage pinion before superfinishing: 2308 (b), and after superfinishing: 2282 (c).

of refurbished gears. There is sufficient material removal to reveal subsurface damage from micropitting, scuffing and corrosion that may be masked by the texture of the used surface. Grinding

Fig. 7: Superfinished intermediate gear assembly (a), characteristic Isotropic Superfinish on the flanks of the same assembly (b): photos courtesy Moventas. JUNE 2011 33

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Fig. 8: Sun pinion gear with several modes of damage including hard line micropitting (a), and the same gear after refurbishment (b).
and in-service wear may cause a smearing of the metal on the gear surface resulting in subsurface damage not only being invisible to the naked eye, but also potentially going undetected by other inspection methods [11]. For example, fig. 4 depicts a cracked gear tooth that was delivered by a customer and deemed suitable for refurbishment. Only after superfinishing did the crack become visible. Consequently, this gear was scrapped and the potential catastrophic failure of the gearbox was avoided. In general, superfinishing can;  uperfinishingcanalsoremovelight(I 25 Km depth) to modS erate (130 mm depth) damage from the gear tooth surface while maintaining geometric tolerances. Figure 5 shows images of the graphite tape lift method that is used to measure and record the amount of micropitting on a gear flank [12]. The deepest micropitting damage is approximately 150 mm (see arrows). In this instance, it is apparent that some

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micropitting remains after superfinishing. The removal of all damage may have compromised the geometry of the gear. However, the peak asperities or stress raisers were removed and the existing micropitting will, in all likelihood, not progress to pitting and eventual spalling [13]. Recently, gearbox manufacturers indicated between 150-250 mm can be safely removed without compromising gear geometry (maximum removal amount is per customer specifications). Gear refurbishment via superfinishing was evaluated for bending fatigue, contact fatigue, and scoring resistance tests on military helicopter gears by the Gear Research Institute (GRI) [14, 15]. Importantly, GRI results suggest that in all three tests, the repaired gears met or exceeded the performance of the new gears. Figure 6 depicts profilometer traces of (a) new ground gear, (b) used gear prior to refurbishment, and (c) used gear after refurbishment via superfinishing. Superfinishing has several distinct advantages over regrinding in terms of time and cost savings. First, the process does not require engineering drawings. Second, all teeth are uniformly and simultaneously finished. For example, the cost per tooth is the same for a small gear with 59 teeth versus a large gear with 113 teeth. Third, as described superfinishing requires less setup time and potential complications versus grinding. Consequently, the turnaround time is rapid. Fourth, typically the ring, sun, and pinion gears of the low-speed stage and the output pinions of the high-speed stage receive the most wear and are refurbished. However, the gears of the intermediate stage, especially an assembled intermediate unit, also can be superfinished with little additional expense since the entire gearbox is removed for maintenance. Figure 7 depicts a refurbished assembled intermediate stage gear.

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A case study was performed on the input stage of a 1.5 MW wind turbine gearbox. The low-speed sun pinion gear usually shows the most damage and will be used here to describe the superfinishing refurbishment process. It should be noted that customers frequently request complete refurbishment of the planetary gears and hollow wheel gear as well. The sun pinion gear is shown in figs. 8a and b. The following protocol was used to refurbish this pinion gear: 1) After the gear was received it was inspected for damage. Micropitting and light abrasive wear were noted. Pre-finishing inspection is crucial as gears may be damaged during decommissioning and/or transport; 2) The initial average surface roughness (Ra) was measured to

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be 0.31 mm (refer to Table 1); 3) The gear was placed in a vibratory finishing apparatus with an optimized media mixture to effect uniform stock removal on the flank; 4) It was processed in active chemistry for a short duration and then carefully inspected for hidden serious damage such as cracks or deep pitting. No seri-

ous damage was detected; 5) The gear was further processed in active chemistry and its surface roughness was periodically monitored with a skidded portable profilometer until the targeted Ra was achieved (a Hommel T1000 Basic with a skidded T1E probe and a 5 mm stylus was used for the case study, with the profilometer cali-

brated to ISO 5436 standard); 6) The pinion was then burnished to remove all traces of the conversion coating; 7) The Ra of the superfinished refurbished gear was determined to be 0.07 mm (refer to Table 2).

resuLts AnD DisCussion

In the case study discussed, the planet and hollow wheel (ring) gears were also successfully refurbished. Customers utilize CMM to determine if the gears are still within tolerances after the parts are returned. All gearswith more than 2300 refurbished to dateremain within the required tolerance. In the majority of cases, all traces of micropitting and other moderate tooth damage can be successfully removed with superfinishing. Even if the micropitting is too deep to remove completely, the peak asperities or stress raisers are removed and micropitting will not progress to pitting and eventual spalling. Moreover, superfinishing will remove the raised lip around the lip of a FOD dent even if the valley of the damaged area is not completely removed. Gears with severe subsurface micropitting or in need of tooth profile correction must be reground first. However, it is still advantageous to use superfinishing as the final step in order to impart a much longer service life. Ongoing field tests, now more than two years old, are being conducted to corroborate that superfinished wind turbine gears have equivalent or superior performance versus new ground gears. Currently, refurbishing wind turbine gears via superfinishing is in commercial operation as a viable replacement to regrinding by a major wind turbine gearbox manufacturer.

ConCLusions
In terms of time, cost, and in-service performance superfinishing has several distinct advantages. The majority of damage sustained on in-service gears in wind turbine gearboxes can be successfully refurbished by superfinishing. Superfinishing is time efficient and economical since all teeth are finished simultaneously versus a few teeth

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Table 1: Ra and Rz measurements taken at different locations on the sun pinion prior to refurbishment.

Table 2: Four Ra and Rz measurements taken at different locations on the sun pinion after refurbishment.

at a time, large gears finish in the same amount of time as small gears, proprietary drawings or expensive reverse engineering is not required, and nital etch inspection is unnecessary. Also, the equipment is inexpensive when compared to regrinding, and setup is simple and does not require extensive operator training. Typically the ring, sun, and pinion gears of the low-speed stage and the pinion gears of the high-speed stage that acquire the most wear are refurbished. However, the gears of the intermediate and assembled intermediate stage can be refinished with little additional expense since the entire gearbox must be removed for maintenance. Also, superfinishing can reveal pre-existing subsurface damage concealed by grinding or in-service wear related smearing. Previous studies by independent sources indicate that refurbishment of used gears by superfinishing results in extended operational life and reduced maintenance costs. And finally, when regrinding may be the only way to remove the deep damage and reshape tooth geometry, superfinishing afterward will result in more-durable surfaces and, hence, a gearbox with greater longevity in the field.

STLE 65th Annual Meeting and Exhibition Wind Turbine Tribology I, May 2010. 3) Juggling with Failure as an Option, Windpower Monthly News Magazine, May 2008. www.windpower-monthly.com 4) Errichello, R., Technical Training Seminars: Gear Failure Analysis, American Gear Manufacturers Association, 2007. 5) Franke, J.-B., Grzybowski, R., Lifetime Prediction of Gear Teeth Regarding to Micropitting in Consideration of WEC Operating States. Presented at DEWEK 2004: The International Technical Wind Energy Conference. 6) Flowers, K., Bearing Repair Provides Valuable Alternative to Bearing Replacement for Heavy Industries, Iron & Steel Technology, 2009, 6 (6), 85-89. 7) Schmid, R., Process for the Modification of Tooth Traces and/or for the Correction of Tooth Trace Deviations of a Gear, United States Patent 6,752,695 B2, May 22, 2004. 8) Arvin, J., Manesh, A., Michaud, M., Sroka, G., Winkelmann, L., The Effect of Chemically Accelerated Vibratory Finishing on Gear Metrology, American Gear Manufacturers Association, 2002. 9) Dini, J.W., Fundamentals of Chemical Milling, Am. Mach., 1984, 128, 113128. 10) Lynwander, P., Gear Drives Systems, Marcel Dekker: New York, 1983. 11) Astakhov, V. P., Surface Integrity in Machining, Ed. J. P. Davim. Springer: 2010; pp. 1-35.

12) McNiff,

B.,

Errichello,

Musial,W.,

Documenting the Progression of Gear Micropitting in the NREL Dynamometer Test Facility, AWEA, 2002. 13) Michaud, M., Summers, E., Superfinishing Large Planetary Gear Systems, European Patent EP1646477, April 29, 2009. 14) Rao, Suren B., Repair of CH-46 Helicopter Gears, Journal of the Reliability Information Analysis Center, First quarter, 2007. 15) Rao, S., McPherson, D., Sroka, G., Repair of Helicopter Gears, American Gear Manufacturers Association, 2005.

ABOuT THE AuTHOrS:

Mark Michaud is with REM Surface Engineering, and Gary J. Sroka and Ronald E. Benson are with the REM Research Group. Visit online at [www.remchem.com].

referenCes:
1) Proactive Service Pays Dividends, Windpower Monthly News Magazine (Supplement), May 2009. www.windpower-monthly.com 2) Dinwiddie, K., Operations & Maintenance Real World Solutions. Presented at the

Printed with permission of the copyright holder, the American Gear Manufacturers Association, 1001 N. Fairfax Street, 5th Floor, Alexandria, Virginia 22314. Statements presented in this paper are those of the authors and may not represent the position or opinion of the American Gear Manufacturers Association.

JUNE 2011

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Alternatives to Gear Grinding

Honing and cup wheel superfinishing can be a cost-effective and higher-quality alternative to gear bore and face grinding. Nagel Precision provides the details.
By Sanjai Keshavan

S
requirements. grinding. lowing ways:

STRINGENT NVH REQUIREMENTS, HIGHER LOADS, AND THE TREND TOWARD MINIATURIZATION TO SAVE WEIGHT AND SPACE ARE FORCING TRANSMISSION GEAR DESIGNERS TO INCREASINGLY TIGHTEN THE SURAND THRUST FACES OF TRANSMISSION GEARS, AS ILLUSTRATED IN FIGURE 1.

FACE FINISH, BORE SIZE, BORE-TO-FACE PERPENDICULARITY TOLERANCES AND FLATNESS ON THE BORES, BORE-TO -

Figure 2 shows tightening of surface finish toltol

erances over the last three decades for automoautomo tive pinion gears, challenging the manufacturing engineers to produce higher quality gears. Surface finish Ra specifications of 20 uin was common in the 1980s, it was then lowered to 8 uin Ra in the 1990s. It is not uncommon to see specifications like < 4 uin Ra for surface finish on bores and faces, 0.0002 bore size tolerance, 0.0002 bore to face perpendicularity and under 20 uin flatness Increasingly, most gears used in high-load applications are following this trend. In many of the gear manufacturing shops that we have seen, grinding is the final processing step for both faces and bores. The goal of this article is to expose manufacturing engineers, especially in shops specializing in small and medium production runs, to cup wheel finishing and honing technology as a potential alternative to Especially in non-automotive environments, pinion gears today are predominantly produced in the foldiameters and relatively deep boreswith length to diameter ratio of 2:1honing has a real advantage in speed of material removal, and over 5:1 deflection of grinding spindle will cause the bore to taper. If a finer bearing like plateau honed finish is desired, neither ID grinding nor double-disk face grinding can achieve it, and a secondary finishing operation typically has to be instituted. Honing and cup wheel superfinishing was devel  ores are first turned, heat treated (for hardened B gears), and then honed or ID ground. Faces are then double-disk ground to achieve final thickness and parallelism.  r after turning and heat treat, a twin spindle ID/ O face grinder is utilized to grind the bore and the face in the same setup. Both processes have their advantages and disadvantages. When the gear faces are double-disk ground there is no control over the bore-to-face perpendicularity, which results in increased NVH during operation. With ID grinding, when performed on a twin spindle machine this problem will be overcome as the part is held in the same position as the face and bore is ground. However, for gears with smaller oped to address these problems, and they have been utilized successfully in the automotive production environment for some time now. In a high volume automotive environment, cup wheel finishing and honing are typically standalone processes. For low- to medium-volume production shops, however, this means two processes as opposed to one. Integrating these two separate, proven processes into a single system now enables low- and mediumvolume gear manufactures access to the same technology utilized by automotive OEMs, eliminating the need for multiple equipment. Figure 3 illustrates a Nagel cup wheel superfinisher and bore honing machine. In this method of processing the gear is cup wheel superfinished by clamping on the bore, and

Fig. 1: Typical tight-tolerance pinion gear.

JUNE 2011

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Fig. 2: Graph illustrating tightening of surface finish tolerances.

then bores are honed by locating on the finished face, yielding excellent bore-to-face perpendicularity. And both honing and cup wheel superfinishing can yield bearing race-type mirror finishes. The SPV 150 cup wheel head is equipped with three servomotors for part rotation, cup wheel head rotation, and cup wheel positioning. The part can rotate up 3,600 rpm, and the wheel up to 2,500 rpm. Upon finishing one face, the part is turned 180 degrees and the other face is finished. The stock removal is split equally between both the faces. The servo-driven machine positioning system can accomplish a part thickness tolerance of .001 (25 um) or higher. For tighter thickness tolerances in tenths of an inchcontact type in-process gauging can be integrated into the machine. The ECO 40 honing head consists of three servo motors for spindle rpm, spindle stroking, and tool expansion. The tool expansion servo can be integrated to machine in-process air sizing or post-process gauging system for automatic tool wear compensation. Or the wear compensation can be accomplished with the touch of a button based on independent offline gage. For bore sizes over 20 mm, an in-process process non-contact type air gage can be imbedded in the tool itself (fig. 4). The gage can detect the type of form error such as taper, hourglass, or barrel-shape, and make automatic adjustments to the honing program to correct the form error. Smaller bores are measured by post process gages, which could be inside or outside the

Fig. 3: Nagel SPV 150 cup wheel face superfinisher and ECO bore honing system.

machine. The machine can be automated or tended manually.

honing AnD iD grinDing

Precision ID grinding machines are several times more expensive than an equally capable honing machine. Even more important is that the accuracy of the grinder is dependent on the machines positioning capability, while accuracy is mostly tooling dependent with a hone. Periodic checks, calibration, and refurbishing are needed to ensure that positioning tolerances stay tight on a grinder. A honing tool, on the other hand, has float built into the tool or fixture, making them less sensitive to positioning accuracy. Unlike a grinding wheel on the end of an arbor, the honing tool isnt subject to spindle deflection. The tradeoff is that any given honing tool is very bore-size specific, so more honing tools need to be stocked than grinding wheels. Another important advantage of honing is that, should a part come off a hone a few microns too small it can be run again, while thats not possible with ID grinding. Also, grinding cant produce honings characteristic crosshatch pattern and plateau finish on the bore surface. This has proven to be a desirable

Fig. 4: In-process gage embedded in Nagel ECO 40 honing tool. 42 gearsolutions.com

feature for maintaining a hydrodynamic lubrication layer for rotating members.

Fig. 5: Illustrates .001mm bore cylindricity and .05 um surface finish after hone.
Bore size permitting, the dual expansion and in-process gauging that can be built in honing permits roughing, finishing, and gauging, and all on one spindle. Getting a fine finished bore starting with a heat-treated surface with one spindle is now a reality. For smaller bores with lower volumes requiring finer surface finish, when dual expansion is not possible the part may have to be rerun with finer stone in a single spindle setup. Honing the parts twiceonce with a coarser stone, and again with a finer stonewould create a finish with deeper valleys and lower peaks, making it a surface suitable for bearings. Figure 5 is a cylindricity trace illustrating 40 uin cylindricity (LHS) and 2 uin Ra plateau hone finish. As it can be observed, the trace has deeper valleys and lower peaks.

JUNE 2011

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Fig. 6: Schematic of Nagel SPV 150 cup wheeel finisher.

Cup wheeL superfinishing AnD fACe grinDing

The SPV 150 face finisher differs from conventional grinding operations. The accuracy of ordinary grinding operations depends on rigid fixturing, as well as the accuracy of the grinding wheels position relative to the part, whereas the SPV 150 utilizes free cutting cup wheels and the tools self dress and conform to the contours of the part. This automatically compensates for inaccuracies in the machine. During this operation, the gear is clamped on the bore diameter and rotated in a direction opposite to that of the cup wheel at a high surface speed. To prevent variations in flatness or

axial runout when finishing flat surfaces, the cup wheel tool substantially overlaps the surface of the part during finishing (fig. 6). The machine can remove as little as a few microns of stock to a few hundred microns very quickly. If the gear is coming straight out of heat treat and a mirror-like finish is desired, another pass may be necessary to accomplish the task. This can be achieved either by rerunning the part or by mounting an automatic cup wheel changer, which would change the wheel quickly and enable roughing and finishing in the same setup. Bore-to-face perpendicularity is comparable with a cup wheel finisher and ID grinder. Cup wheel superfinishers can yield finer finishes, though, and are not as dependent on machine accuracies as grinders are. Double-disk face grinding, on the other hand,

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Fig. 7: Comparision of bore to face perpendicularity and flatness after grinding and cup wheel face finishing.
yields a higher production rate and excellent parallelism between faces. They do not impact the bore to face perpendicularity tolerance, however. Figure 7 provides a comparison of bore-to-face perpendicularity and flatness on a cup wheel finished face vs a double-disk ground face. In conclusion, the honing and cup wheel processing that has long been the predominant way of making pinion gears in high-volume automotive applications is now possible in a lower- and medium-volume environment.

ABOuT THE AuTHOr:

Sanjai Keshavan is manager of the ECO Hone Division of Nagel Precision, Inc. Call (734) 426-1812 or go to [www.nagelusa.com].

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Gear Expo

Reducing Gear Rattle

The professionals at Muncie Power Products help you to addressand eliminategear noise/rattle one step at a time.
By Mikel Janitz

W
TO THE TOP CULPRITS. SATISFACTION.

WORK TRUCKS ARE GETTING QUIETER, DRIVING THE NEED FOR AXILLARY POWER TO DO THE SAME. WHILE GEAR NOISE, WHINE, AND RATTLE ARE NOT NEW, THEY ARE MORE NOTICEABLE TODAY SINCE MOTORS AND POWERTRAINS ARE QUIETER. GIVEN THAT THIS IS THE CASE, WE CONDUCTED TESTS TO IDENTIFY AND ISOLATE PARTICULAR

FEATURES THAT CAUSE NOISE. BASED ON THESE TESTS WE HAVE BOILED THEM DOWN THE FOLLOWING INFORMATION HIGHLIGHTS AND PRIORITIZES THE FEATURES

WE DISCOVERED TO HAVE THE GREATEST IMPACT ON NOISE. CONSEQUENTLY, BY ONSEQUENTLY ONSEQUENTLY, ADDRESSING THESE FEATURES IN DESIGN OR MANUFACTURING, WE CAN IMPROVE OR

SIGNIFICANTLY REDUCE NOISE AND RATTLE. MOREOVER, WE CAN IMPROVE CUSTOMER

CreAting A bAseLine
The first step in the process was to create a baseline. Baseline noise testing was conducted on a diesel-powered Class 3 cab with an automatic transmission (refer to the graph accompanying this article for details). Before the gear set was mounted measurements for external backlash, gear quality, internal backlash, and endplay were recorded. All improvements are based on these measurements. The gear set was run at idleapproximately 700 rpmthe noise level recorded, and a baseline established. The red line on the graph represents the unacceptable sound level from that test. From this point the team started working on particular features to improve or reduce noise and rattle one step at a time. Now lets look at the graph, which depicts the impact on noise level as each feature is addressed. As you can see the baseline is well above the acceptable level. The noise was unacceptable to customers due to many factors, including excessive backlash between the transmission output gear and the input gear, reduced gear quality, smaller gear pitch, high internal backlash between gears, gear centerlines at top of tolerance, and high bearing endplay. One additional feature affecting noise is the presence of drag, or the lack of sufficient drag, which impacts noise and rattle in any form. Drag will be discussed last. It is also noted here that the graph indicates that the features are additive. Each feature

can therefore reduce noise by some amount. Noise can also be reduced proportionally to the number of features improved. It was discovered that one can change features, but the backlash between the transmission gear and gear set must be addressed first or the other steps have minimal impact. The design of backlash has its limitations. Consequently, backlash is controlled at installation and during gasket selection. Care must be taken to properly mount, install the gear set, and torque the fasteners to achieve optimal noise levels. This is in the control of the installer at this point. After reducing the backlash between the transmission and gear set, the next feature worked on was gear quality. Improving gear quality can be costly. It is important to understand the relationship of manufacturing cost vs. reduced noise. It was demonstrated that higher gear quality and gear pitch reduced noise. The reduction was not only measurable, but also detectible to the human ear. Note that the gear quality went from a baseline of AGMA 8 to AGMA 10. Gear quality was the second-highest contributor to reduce noise, and therefore the second feature on the graph.

ControLLing bACkLAsh
The next step taken to reduce noise focused on internal backlash and centerline control. These are combined since they are so closely

JUNE 2011

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backlash, but the results show that this had little effect in reducing rattle and noise that is detectible to the human ear. This was an important finding, but this step had the smallest impact on reducing noise of all those we addressed. Rattle and noise create sound waves that we feel and hear. The waves of sound come from vibration between the gear, shaft, and bearing set. If the bearing set is looseexcessive endplay >.003, for examplethe vibrations are more pronounced, and the noise is noticeably louder. Rattle is a huge customer dissatisfaction issue. If the endplay is reduced, the noise is reduced proportionally. The baseline endplay was excessive, and consequently the noise was unacceptable. When the endplay was reduced by 25 percent, the noise was reduced as well. Endplay cannot be related. This is a cost-effective means to reduce noise. Accurate CNC equipment, programming, and tooling must be used in manufacturing to hold and repeat tight centerline tolerances. Testing indicated that it is necessary to control internal backlash before moving to the next step. It is important to specify and control internal completely eliminated, however, therefore rattle cannot be completely eliminated. If it were, bearings would burn up, and then you have a completely different issue to

Fig. 1: Baseline noise testing was conducted on a diesel-powered Class 3 cab with an automatic transmission.

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contend with. Bearings need to be sized properly, lubricated appropriately, and allowed to expand while in use. Endplay is last on the list to address, but there are other issues impacting rattle including gear size, inertia, weight, material, and geometry, just to name a few. These features were not addressed at present, as it would require significant time with simulation and 3D modeling to go down that path.

drag element in series with other features discussed will reduce noise, as well. The downside of introducing a drag element is the inefficiency it creates. It creates heat and requires power (uses fuel) to overcome resistance forces. The graph also indicates that noise was at an acceptable level with only a drag element without other features improved. The question then becomes whether the inefficacies can be tolerated, and can operating costs justify the reduction in noise? Drag can come in many forms; for example, tight bearings, excessive hydraulic fluid levels, friction between clutch plates, and shaft loads. Other designed parts can be introduced to create drag, as well. Drag was last on the list to work on because of

the negative aspects associated with it. The graph shows noise can be reduced to acceptable levels without drag, but it also shows that noise can be reduced by doing nothing other than adding drag.

ConCLusion
Noise and rattle are big customer concerns today. Gear manufacturers and users of gear sets are working together to balance noise, rattle, and efficiency, as well as cost. Product design engineers are working with manufacturing engineers to produce the most-quiet gear set economically available. And test engineers and lab technicians will keep testing and reporting results so that we can continually improve customer satisfaction.

introDuCing DrAg
The last feature studied was the effect of drag on the noise in a gear train. In the graph the orange line represents the baseline gear set with the addition of drag only. A drag element by itself will reduce noise if the drag force is significant enough. A

ABOuT THE AuTHOr:

Mikel Janitz graduated from Oklahoma State University with a masters degree in engineering management and is manager of engineering at Muncie Power Products. Call (800) 367-7867 or go to [www.munciepower.com].

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new products, equipment, and resources

ShoWCaSe

A new advanced version of SKF Speedi-Sleeve that offers exceptional performance in radial shaft sealing applications is now available from SKF. The new generation SKF Speedi-Sleeve and SKF radial shaft seals offer an enhanced sealing system performance with improved reliability and extended maintenance intervals, while enabling users to restore malfunctioning sealing systems without having to disassemble machines or regrind shafts. It is intended for OEM and aftermarket applications in diverse industries. The solution finds use in industrial gearboxes, electrical equipment such as motor shafts, off-highway construction, and agricultural vehicles, and mining and mineral processing equipment. To learn more contact Julian Webb at (224) 535-4438 or julian.k.webb@skf.com. Visit online at [www.skf.com].

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CImteCH 310 Synthetic metalworking Fluid

CIMTECH 310a low-pH synthetic fluid designed to meet the stringent requirements of the automotive and aerospace industrieshas become the standard metalworking fluid for many manufacturers. The product, manufactured by global supplier Cimcool Fluid Technology, passes all bi-metallic and aluminum (7075) sandwich corrosion tests. It is recommended for machining and grinding operations, including creep feed grinding on non-ferrous or ferrous metals. Designed for moderate- to heavy-duty operations, CIMTECH 310 is low foaming and provides excellent rancidity control, extending the life of the fluid and minimizing the need for additives. In addition, it offers unmatched lubricity providing long tool life and outstanding surface finish. Learn more at [www. cimcool.com].

Super turbo Chamfer mills from Seco tools

Seco Tools has announced a new line of Super Turbo chamfer mills designed to provide high metal removal rates while reducing production costs. The new cutters use the same inserts and hardware as standard Super Turbo square shoulder mills, allowing manufacturers to increase the versatility of their operations without additional spare parts. The new Super Turbo chamfer mills feature a high positive cutting rake angle and positive helix angle to reduce power consumption, resulting in freer cutting and reduced harmonics. The design increases tool life as compared to standard APxx style cutters, helping to reduce cost per part. The new chamfer mills use the same strong insert pocket design found in the rest of the Super Turbo family of products. Call (248) 528-5444 or visit [www.secotools.com/us].

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Upgraded HtA Honing System from Sunnen

The new all-electric HTA hone brings increased part capacity and stroker torque to applications such as bore resurfacing of hydraulic cylinders, extruder barrels, and die casting shot tubes, or manufacture of gas flow meter tubes and repair of actuators for construction, mining, farming, and forestry equipment. The machine is available in two standard model sizes: the HTA2100 for 6.9-foot (2.1 m) part lengths, and the HTA-4100 for 13.5-foot (4.1 m) part lengths, accommodating true 2- or 4-meter parts. Both models handle parts with bore ID of 2.5 to 21 inches (63.5 533 mm) and maximum part OD of 24 inches (610 mm), and part weights to 8000 pounds (3628.7 kg). Call (800) 325-3670, e-mail sales@sunnen.com, or go to [www.sunnen.com].

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o-INSPeCt multisensor measuring machine from Carl Zeiss

The successful O-INSPECT Multisensor Measuring Machine from Carl Zeiss allows the very easy, very accurate, and thus very efficient inspection of complex parts. It can be used in the electronics and plastics industries, for medical and automotive technology, and precision engineering. A chromatic white light sensor is now available for O-INSPECT. This sensor enables the measurement of parts that cant be captured with a contact sensor or a camera, including very small and sensitive workapieces that feature a transparent, glossy or low-contrast surface. Reflections or lack of contrast, which can impede the correct focusing of a camera, will no longer be a relevant factor. Learn more by going online to [www.zeiss.com].

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twin Cutter Boring System from BIG Kaiser

BIG Kaisers 319 SW series is an exceptionally rigid, new style, twin cutter rough boring system. These corrosion-resistant boring heads offer a unique feature; by simply reversing the insert holders, users can switch between balanced and stepped cutting. The 319 SW series will replace the older 314 RW series. By not introducing additional components or having to manually adjust insert height for different roughing methods, the 319 series reduces setup time and eliminates the need for a presetter due to fixed tool heights and a diameter scale on the tool. With a diameter range .787-8.000 the tools utilize standard carbide inserts (CC, SC, and SP) and provide coolant-through direct to the cutting edge to improve chip evacuation and lengthen tool life. Call (847) 228-7660, e-mail bigkaiser@bigkaiser.com, or visit [www.bigkaiser.com].

FeeLer milling Lathes and turning Centers from methods

Methods Machine Tools, Inc., a leading supplier of innovative precision machine tools, has introduced high performance FEELER milling lathes and turning centers featuring extensive design and engineering by Methods, designed to provide users unsurpassed performance and value. FEELER lathes and turning centers are backed by Methods application expertise, support, and extensive network of technology centers. The Methods-FEELER CNC lathes and turning centers include the HT-Series, FTC-Series, and FT-Series, with a full range of equipment including vertical machining centers, bridge mills, and boring mills. More information is available by calling (978) 443-5388, e-mail sales@ methodsmachine.com, or visiting online at [www.methodsmachine.com].

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< continued from page 18 start measuring immediately. The absolute encoders provide probing volumetric accuracy down to 0.023mm depending on the model. The articulating arm also features low profile, Zero-G counterbalance to stabilize its weight for one-handed operation and effortless control above and below its centerline. ROMERs tube inspection system utilizes the Data Overlay Camera System (DOCS) software platform. Pictures can be taken with the arms onboard digital camera, and DOCS overlays the tube wire frame onto the digital picture. This enables the inspection report to show exactly how the tube was supported or fixtured during measurement. DOCS communicates with most CNC bender interfaces, so corrected bend data can be sent directly to the CNC bending machine, reducing the process of trial and error associated with manual measurements. DOCS user training is generally two days, as compared to five to six days for traditional CMM software. Hexagon Metrology serves the high precision measurement and inspection needs of worldwide manufacturers with its extensive line of metrology hardware, software, accessories and customer services. More information is available at [www. hexagonmetrology.us].

Siemens to Service electric arc furnaces in United States

Siemens Industrys Metallurgical Services Offline Maintenance business segment announces they are providing support, repair, and fabrication of Electric Arc Furnace (EAF) components from its Milan, Ohio, facility. EAFs are used to recycle scrap metals into usable product. Siemens is now the first EAF original equipment manufacturer to offer these services within the United States. Siemens also produces EAF equipment from its facility located in Monterrey, Mexico, and will continue to use both plants based on the needs of its customers. However, this location addition allows Siemens to offer its domestic customers several advantageous benefits, including reduced logistical obstacles in freight costs, customs clearance, and transit time which in the past often made repair jobs cost-prohibitive. By manufacturing EAF components such as water-cooled panels, as well as offering service repair, from its northwest Ohio facility, Siemens can provide shorter turnaround times and varying cost-effective savings for customers based in the United States. The strategy of an OEM offering these services domestically is a great step for Siemens, says Robert Strain, account manager for Siemens Metallurgical Services. Weve already seen a significant increase in lower volume and short lead time water-cooled panel orders, not to mention inspection and repair projects. Customers appreciate having the option

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production, transportation, and building technology solutions. The companys integrated hardware and software technologies enable comprehensive industry-specific solutions for industrial and infrastructure providers to increase their productivity, sustainability, and profitability. Learn more at [www.usa.siemens. com/industry].

C4 to Represent Complete Mitsubishi product Lineup

MC Machinery Systems, Inc., is pleased to announce that Oklahoma distributor, C4 Incorporated, will now represent the complete Mitsubishi product lineup. With a total supply chain of complementary technologies, Mitsubishi has the experience and equipment solutions to help U.S. manufacturers achieve maximum productivity in every industry. Since 1972 C4 has been serving the machine tool industry with cutting tools, consumables, and EDM. Until now C4 Incorporated represented Mitsubishi EDM and waterjet, but the recent addition of Mitsubishi laser and press brake completes the offering. We are excited to add a local presence for these lines in Oklahoma, says Mitsubishi Marketing Manager Pat Simon. C4 is recognized in the industry as a reliable source for manufacturing equipment. They know the market well and were confident that the relationship with Mitsubishi will further cement their reach in the Oklahoma fabricating market as well. We are excited to expand our product offering, says C4 President Ed Raschen, and by providing the complete Mitsubishi supply chain well be able to deliver total manufacturing solutions to the full customer base in our territory. Mitsubishis superior products are backed by industry-leading service and support. For more information visit [www.mitsubishi-world.com]. Also visit [www.c4industrial.com].

of a quick turnaround while still receiving an OEM quality product. The Milan facility is a full-service maintenance workshop that specializes in design, engineering, heavy fabrication, lifting device fleet management, and housing a comprehensive inventory of spare parts. Siemens Industry, Inc., is the U.S. affiliate of Siemens global Industry Sector businessthe worlds leading supplier of

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FEATUREDsuppliers
Midwest Gear Corporation REF #101 Phone: 330-425-4419 Fax: 330-425-8600 Email: sales@mwgear.com Website: www.mwgear.com New England Gear REF #102 Phone: 860-223-7778 Fax #:860-223-7776 Email: jeff@newenglandgear.com Website: www.newenglandgear.com R. P. Machine Enterprises, Inc. REF #103 Phone: 704-872-8888 Fax #:704-872-5777 Email: sales@rpmachine.com Website: www.rpmachine.com Repair Parts, Inc. REF #104 Phone: 815-968-4499 Fax #:815-968-4694 Email: rpi@repair-parts-inc.com Website: www.repair-parts-inc.com Havlik International Machinery, Inc. REF #105 Phone: 519-624-2100 Fax: 519-624-6994 Email: havlik@bellnet.ca Website: www.havlikinternational.com GQ Machinery Inc. REF #106 Phone: 516.867.4040 Fax: 516.223.1195 Email: george@gqmachinery.com Website: www.gqmachinery.com

MaCHinErY
Contact Gear Solutions at 800-366-2185 to list your machinery.
BARBER-COLMAN #16-36, 24 Dia, C-Frame Style, 4 1/8 Bore REF#103 BARBER-COLMAN #16-56, 16 Dia, 56 Face, Differential REF#103 BARBER-COLMAN #22-15, 22 Dia, 14 Face, Differential REF#103 DAVID BROWN, 138 Dia, Face 60REF#103 G&E #24H Universal Head, Infeed, Tailstock, Differential, 50s REF#103 HAMAI #120, 4.8 Dia, 4 Face, 12 DP, 70 REF#103 LIEBHERR #L-402, 16 Cap, 2-Cut Cycle, Crowning, 77 REF#103 LIEBHERR #L-650, 26" Dia Cap, 14.5" Face, 2.5 DP, New 70s REF#103 MODUL #ZFZW 800, 29.8 Dia, 16.25 Face, 2.5 DP Crowing, 2-Cut REF#103 BARBER-COLMAN #1600-36, 16" Dia., 39.5" Face, 6 DP REF#103 CHONG QIN #Y3180H, 31.5 Dia., 15" Face, 3 DP REF#103 FELLOWS FH-200 Max Diam 7.87" Max Dia Pitch 5.08" REF#103 G&E #16H Gear Hobber, 16"Dia REF#103 BARBER-COLMAN #3 (6-10), Single & Triple Tread Worm HS REF#103 BARBER-COLMAN #6-10, 6 Dia, 10 Face, 16 DP REF#103 KOEPFER #140 , 2.75 DIa, 4 Face REF#103 KOEPFER #153B, 5.6 Dia, 5.9 Face REF#103 LANSING #GH-50, 50 Dia, 17.75 Face, 2 DP REF#103 LIEBHERR #L-252, 9.8 Dia, 7.9 Face, 4.2 DP REF#103 MIKRON #79 1.5 Dia, 26 DP REF#103 BARBER-COLMAN TYPE T REF#103 IUG Craiova FD-3600 REF#103 LIEBHERR #L-401, 15.7 Dia 11 Face, 3DP REF#103 G&E #36HS 36Dia, 14 Face 3 DP REF#103 PFAUTER #P-3000, 120 Dia, Single Index REF#103 SCHIESS RFW-10-S 55 Dia REF#103 SHIBURA HHC-250A Single Index REF#103 OVERTON #HD-400, 15.7 Dia, 12 Face, 3 DP, New 88 REF#103 SCHIESS 1 RF-10, Dia 60 150 L, .50 DP REF#103 G&E #40TWG, 48 Dia, 18 Face, 3 DP REF#103 G&E #60S, 72 Dia, 14 Face, 1.25 DP REF#103 G&E #72H, 72 Dia, 24 Face, 1 DP REF#103 G&E #96H, 104 Dia, .50 Face, 1.25 DP REF#103 PFAUTER #P-630, 25 Dia REF#103 PFAUTER #2500, 100 Dia REF#103 TOS FO-16, Max Cut w/support 90 REF#103 PFAUTER P250 10 Dia REF#103 GE Hobber 200 Dia, 55 Face REF#103 GE/Fitchburg Hobber 32 Dia, 72 Face 1.25DP REF#103 JF Reinecker 40 Dia 35 Face REF#103 LIEBHERR L-160-R 6.5 Dia REF#103 MIKRON #102.04 , 4 Dia, 5 Face REF#103 NIHON-Kikai NDH-1200 50 Dia REF#103 PFAUTER P-900 36 Dia REF#103 SCHIESS RF 40/60S 240 Dia 100 Face REF#103 BARBER-COLMAN #25-15 25 Dia, 15 Face, 2.5 DP REF#103 CRAVEN Horizontal , 18 Dia and 100 Length REF#103 KOEPFER #173B, .6.1 Dia, 7 Face REF#103 PFAUTER #P-630R, 25" Max. Spur Dia, 12" Max Rotor Dia. 12" REF#103 BARBER-COLMAN 2 1/2 -4, S/N 119, 62 Hi-Production Spur Gear REF#104 BARBER-COLMAN 6-10 SYKES, Triple Thrd w/Lever Operated Collet Assy REF#104 BARBER-COLMAN 6-10 B&C Ltd, S/N 8079, Triple Thrd REF#104 BARBER-COLMAN 6-10, S/N 4626, 57 Triple Thrd 3 Hob Slide REF#104 BARBER-COLMAN 6-10, S/N 4659R, 56 Triple Thrd Adj Ctr Assy REF#104 BARBER-COLMAN 6-10, S/N 4665, 57 Fine Pitch Prec Triple Thrd REF#104 BARBER-COLMAN 6-10, S/N 4701, 58 Triple Thrd w/Power Down Feed REF#104 BARBER-COLMAN 6-10 M/C, S/N 4755, 59 Triple Thrd w/MC Conversion REF#104 BARBER-COLMAN 6-10 Multicycle, S/N 4778R87, 60 (87 Rebuild), Sgl Thrd Hi-Spd REF#104 BARBER-COLMAN 6-10 M/C, S/N 4913, 63 Triple Thrd w/90 Deg Hob Slide REF#104 BARBER-COLMAN 6-10 Multicycle, S/N 5055, 66 Triple Thrd, 800 RPM REF#104 BARBER-COLMAN 6-10, S/N 5141, 67 Triple Thrd w/Prec Hob Shift REF#104 BARBER-COLMAN 6-10 Multicycle, S/N 5148, 68 Triple Thrd, 800 RPM REF#104 BARBER-COLMAN 6-10 Multicycle, S/N 5259, 75 Triple Thrd w/Auto Hob Shift REF#104 BARBER-COLMAN 6-10, S/N 5353, 77 Triple Thrd w/3 Hob Slide, 800 RPM REF#104 BARBER-COLMAN 6-10, S/N 5394, 81 Fine Pitch Triple Thrd w/Dwell & Hob Rev REF#104 BARBER-COLMAN 6-16 M/C, S/N 5238, 70 Triple Thrd, Recon 02 REF#104 BARBER-COLMAN 6-10, S/N 5407, 82 Auto w/PLC Control REF#104 BARBER-COLMAN DHM, S/N 105, 42 Double Thrd REF#104 BARBER-COLMAN 14-15, S/N 635R, 53 Dbl Thrd, Fact Reb REF#104 BARBER-COLMAN 14-15, S/N 745, 55 Dbl Thrd w/Dwell REF#104 BARBER-COLMAN 14-15 Dual Fd, S/N 938, 62 Dbl Thrd, Comp Reco REF#104 BARBER-COLMAN 14-15, S/N 1055, 65 Dbl Thrd w/New Hyd Sys REF#104 BARBER-COLMAN 14-15, S/N 1131, 66 Dbl Thrd w/Hyd Tailctr REF#104 BARBER-COLMAN 14-15 Dual Fd, S/N 1261, 67 Dbl Thrd w/Hyd Live Ctr REF#104 BARBER-COLMAN 14-15 Dbl Cut, S/N 1278, 68 Dbl Thrd w/4-1/8 Bore REF#104 BARBER-COLMAN 14-30 Dual Fd, S/N 1371, 71 4-Thrd w/Sizing Cycle REF#104 BARBER-COLMAN 22-15, S/N 923, 62 Dbl Thrd, Dbl Cut REF#104 BARBER-COLMAN 16-11, S/N 184, 50 Dbl Thrd w/Vert DRO REF#104 BARBER-COLMAN AHM, S/N 1896, 42 Sgl Thrd w/3 Jaw Chuck REF#104 BARBER-COLMAN 16-16, S/N 2745, 51 Sgl Thrd w/90 Deg Hd REF#104 BARBER-COLMAN 16-16, S/N 3171, 53 Dbl Thrd, Spanish Nameplates REF#104 BARBER-COLMAN 16-16, S/N 3580, 59 Dbl Thrd w/Diff & Auto Hobshift REF#104 BARBER-COLMAN 16-16 Multicycle, S/N 3641, 60 Dbl Thrd w/Diff REF#104 BARBER-COLMAN 16-16, S/N 3660, 57 Sgl Thrd REF#104 BARBER-COLMAN 16-16, S/N 4136, Dbl Thrd, C Style End Brace w/Diff REF#104 BARBER-COLMAN 16-16 Multicycle, S/N 4170, Dbl Thrd w/Jump Cut Cycle C Style REF#104 BARBER-COLMAN 16-16, S/N 4473, 73 4-Thrd w/Workclamp Cyl C Style REF#104 BARBER-COLMAN 16-16 Multicycle, S/N 4520, 75 Dbl Thrd w/Gooseneck Slide REF#104 BARBER-COLMAN 16-16 Multicycle, S/N 4631, 79 C Style End Brace, 4W Adj Ctr REF#104 BARBER-COLMAN AHM (36), S/N 1152, 42 Dbl Thrd REF#104 BARBER-COLMAN 16-36, S/N 4090, 66 Dbl Thrd, C Style End Brace REF#104 BARBER-COLMAN 16-36 Multicycle, S/N 4232, 68 Dbl Thrd C Style End Brace w/Diff REF#104 BARBER-COLMAN 16-56, S/N 3136R84, 53 (Reb 84), Dbl Thrd REF#104 BARBER-COLMAN 10-20, S/N 6700045890, 76 Dbl Thrd w/2 Cut Cycle REF#104 TOS OFA Series Conventional Gear Hobbers, 12 & 40 Dia REF#105 TOS OHA Series Conventional Gear Shapers, 12 & 40 Dia REF#105 GEar Pinion HoBBErS & SPLinE MiLLErS HURTH #KF-32A 15 Dia, 59 Face, 67 REF#103 GE/Fitchuburg Pinion Hob 32 Dia, 72 Face REF#103 MICHIGAN Tool #3237 REF#103 SCHIESS 1 RF-10, 60 Dia REF#103 WANDERER GF 345 CNC Hobbing /Milling Machine 4-Axis 24" Swing x 240 Length REF#103 FITCHBURG Pinion Hobber 42 Dia, 72 Dia REF#103 CRAVEN Horizontal, 18 Dia and 100 Length REF#103 GEar HoB & CUttEr SHarPEnErS (incl CnC) ARTER #A-12, 12 Rotary Surface Grinder for Sharpening Sharper Cutters REF#103 BARBER-COLMAN #6-5, 6" Dia, 5" Length, Manual Dresser, 57 REF#103 BARBER-COLMAN 10-12, 10" Dia, 12" Length, Spark Out REF#103 FELLOWS #6SB, Helical Cutter Sharpener, 6 Dia, up to 50 Degrees REF#103 KAPP #AS-305GT, 1 DP, 28" Grind Length, 10" Diam., Str. & Spiral REF#103 KAPP #AS204GT, 10 Dia, Wet Grinding, CBN Wheels, 82 REF#103 BARBER-COLMAN #3 HS, Hob Sharpener, 4" Max. OD., 4" REF#103 BARBER-COLMAN #4-4HRS, Hob Sharpener, 4" Max. OD. 4" REF#103 REDRING MODEL #SGH "PREIFORM" SHAVE CUTTER GRINDER/SHARPENER REF#103 STAR 6X8 HOB SHARPENER PRECISION GEAR & SPLINE HOBBER REF#103 BARBER-COLMAN 2-2 1/2 , 2.5 Dia REF#103 KAPP #AST-305B, 27.5 Dia, REF#103 KAPP AS-410B REF#103 GLEASON #12 Sharpener, 3-18 Cone REF#103 BARBER-COLMAN 2 1/2-2, S/N 16, 66 Wet w/Auto Feed REF#104 BARBER-COLMAN 6-5, S/N 110R, 55 Wet w/Auto Dress & Sparkout REF#104 BARBER-COLMAN 6-5, S/N 396, 66 Wet w/Auto Dress & Sparkout REF#104

GEar aCCESSoriES, PartS & tooLinG FELLOWS Model #10-4/10-2, All Parts Available REF#102 Tilt Tables for 10-2/10-4, Qty 2 REF#102 FELLOWS Parts Available For All Models REF#103 BARBER-COLMAN PARTS AVAILABLE FOR ALL MODELS REF#103 G&E PARTS AVAILABLE FOR ALL MODELS REF#103 GEar HoBBErS/CUttErS CnC LIEBHERR #LC-255 CNC, 6-Axis, 10 Dia, 10 Face, 4 DP, 87 REF#103 PFAUTER #PE-150, 6-Axis CNC, 6 Dia, 5 DP, 6 Face, Fanuc 18MI REF#103 SYKES #H160, 4-Axis CNC Hobber, 6 Dia, All the Features, 93 REF#103 G&E #60 S-2 CNC Gasher/Hobber REF#103 G&E #60SB-2C CNC, Gasher/Hobber REF#103 BARBER-COLMAN #16-36, 16 Dia, 4-Axis, 6 DP, 36 Face REF#103 LIEBHERR #LC-502 6-Axis CNC Gear Hobber, 20" Diam. Cap., Loading REF#103 LIEBHERR #L-652, 5-Axis 26 Dia,27 Face, 2 DP 09 REF#103 MUIR CNC Gear Hobber, 4-Axis, 118 Dia REF#103 LIEBHERR #L-252 3-Axis, 9.8 Dia, recontrolled 2008 REF#103 LIEBHERR #ET-1202 CNC - 70 Dia Internal, Single REF#103 LIEBHERR #ET-1802 CNC 98 Dia Internal, 3-Axis REF#103 MITSUBISHI GD-20 CNC, 5-Axis, 8 Dia REF#103 G&E 120/188, CNC Gasher/Hobber, 188 Dia (5 Meter) REF#103 G&E #120GH, CNC, Gasher/Hobber, Twin Stanchion, 1/2 DP, 42 Face, 94 REF#103 PFAUTER P400H, 5-Axis, 18 Dia, 1 DP, Recontrolled 03 REF#103 G&E #160GH, CNC, Gasher/Hobber, New 07 REF#103 G&E #96GH, CNC, Gasher/Hobber, New 09 REF#103 HAMAI 60SP, CNC 4-Axis, 3.5" OD, 9" Face, 12 DP, New 89 REF#103 PFAUTER PE 300 AW CNC 6-Axis REF#103 GEar HoBBErS/CUttErS PFAUTER P1251 Hobbers s/n 25-276 and 25-277 REF#102 PFAUTER (1) RS-00 s/n 17593 REF#102 BARBER COLEMAN (1) 16-36 multi cycle s/n 4404 REF#102 BARBER-COLMAN #16-16, Multi-Cycle, Dual Thread Worm and/or Single Thread Worm REF#103 G&E #48H 48 Dia, 18 Face 2 DP, Universal REF#103 G&E #48H, 48 Dia, 35 Face, 3 DP, Gooseneck Attachment REF#103 LEES BRADNER HH-144 16 Dia, 144 REF#103 BARBER-COLMAN #6-16, 6 Multi-Cycle REF#103 G&E #36H Differential, Excellent Condition REF#103 BARBER-COLMAN #14-30, 14 Dia, 30 Face, 3.5DP REF#103 PFAUTER P-251 10 Dia, 9.6 Face, 4 DP REF#103 BARBER-COLMAN #14-15, 14 Dia, 15 Face, 1 to 4 Start Worm, Several REF#103 BARBER-COLMAN #16-16, 16 Dia, 16 Face, 6DP REF#103

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BARBER-COLMAN 6-5, S/N 433, 69 Wet w/Auto Dress & Sparkout REF#104 BARBER-COLMAN 10-12, S/N 643R83, Wet w/Auto Dress, PC Control, Fact Reb 83 REF#104 TOS OHA Series CNC Gear Shapers, 12 & 40 Diameter REF#105 TOS OFA Series CNC Gear Hobbers, 12 & 40 Diameter REF#105 GEar SHaPErS CnC 36 Shapers, 14 Throat Risers, 53 of Swing, Qty 3 REF#102 FELLOWS #10-4/10-2, Qty 150 REF#102 HYDROSTROKE #50-8, Qty 2 REF#102 HYDROSTROKE #20-8, Qty 5 REF#102 HYDROSTROKE #FS630-125, Qty 1 REF#102 HYDROSTROKE #FS400-90, Qty 2 REF#102 FELLOWS #20-4, Qty 6 REF#102 FELLOWS #48-8Z, Qty 1 REF#102 FELLOWS #FS-180, 3-5 Axis, 7 Dia, 1.25 Face., 6 DP, New 88 REF#103 LIEBHERR #WS-1, 4-Axis CNC, 8" OD, 2" Stroke, Fanuc 18MI REF#103 LORENZ # LS-180, 4-Axis CNC, 11 OD, 2 Stroke, 5 DP REF#103 LORENZ #LS-304 CNC Gear Shaper 5-Axis Heckler & Koch Control REF#103 LORENZ #LS-156 CNC Gear Shaper Dia 6 REF#103 FELLOWS FS400-125, 16 Dia, 3.5 DP 5 Face REF#103 SCHIESS RS-20 S, 12 Stroke, 118 Dia REF#103 FELLOWS #10-4 3-Axis (A/B), 10" Dia, 4" Face, 4 DP New .09 REF#103 RP-GS 800 CNC, 4-Axis, Max Dia 31.5, Face 9, 2.5 DP REF#103 RP-GS 400 CNC, 6-Axis, Max Dia 15 Face 4, 3 DP REF#103 STANKO /RPM #48-8 Gear Shaper CNC, Fanuc 18 REF#103 FELLOWS #10-4 2-Axis, 10 Dia 4 Face REF#103 FELLOWS #20-4 3-Axis 10 Dia, 4 Face REF#103 FELLOWS FS400-90 Hydro-stroke Gear Shaper CNC Nominal Pitch 15.7" REF#103 RP-GS 1500 CNC, 4-Axis, Max Dia 49.2, Face 12, 2 DP REF#103 GEar SHaPErS FELLOWS #10-2, (10 Dia), 2 Face REF#102 FELLOWS #10-4, (10 Dia), 4 Face REF#102 FELLOWS (200) 10-4 / 10-2 Shapers REF#102 FELLOWS (1) 50-8 Hydrostroke Shaper s/n 36607 w/ 6 axis 16iMB Fanuc (2009) REF#102 FELLOWS (1) 20-8 Hydrostroke Shaper s/n 35932 w/ 6 axis 16iMB Fanuc (2009 REF#102 FELLOWS (1) #7 125A Face Gear Machine REF#102 FELLOWS (2) #3 Face Gear Machine REF#102 (1) 4ags with adjustable Helical Guide s/n 30634 REF#102 (1) #7 125A adjustable Helical Guide REF#102 FELLOWS (1) FS630-200 Hydrostroke Shaper s/n 36943 w/ 6 axis 16iMB Fanuc (2009) REF#102 FELLOWS (3) Tilt Table 10-4 / 10-2 w/ 4 axis 21i Fanuc Controller (2009) REF#102 FELLOWS (2) Swing-away center support for 10-2 / 10-4 REF#102 FELLOWS (1) FS630-170 Hydrostroke Shaper s/n 36732 w/ 6 axis 16iMB Fanuc (2009) REF#102 FELLOWS (2) FS400-170 Hydrostroke Shaper w/ 6 axis 16iMB Fanuc (2009) REF#102 FELLOWS (4) FS400-125 Hydrostroke Shaper w/ 6 axis 16iMB Fanuc (2009) REF#102 FELLOWS (1) 20-4 Shaper s/n 35687 w/ 4 axis 21i Fanuc Controller (2009) REF#102 FELLOWS (1) 48-8Z Shaper w/ 14 throated riser (53 of swing) REF#102 FELLOWS (1) Horizontal Z Shaper s/n 21261 REF#102 FELLOWS (1) 4-B Steering Sector Gear Shaper w/ 18iMB 4 axis Fanuc controller s/n 34326 REF#102 FELLOWS (1) 36-10 Gear Shaper REF#102 FELLOWS (1) 10x6 Horizontal Z Shaper REF#102 FELLOWS (1) 36-6 Gear Shaper w/ 13 riser s/n 27364 REF#102 FELLOWS (1) 10-4 Shaper w/ 3 riser w/ 4 axis 21i Fanuc Controller (2009) REF#102 All Parts for 10-4/10-2 Fellows Gear Shapers REF#102 FELLOWS #36-8, 36 Dia, 8 Face REF#103 FELLOWS #100-8 100 Dia, 8 Face REF#103 FELLOWS #612A, 615A, #645A REF#103 FELLOWS #10-4, 10 Dia, 4 Face, 4 DP REF#103 FELLOWS #4A Versa, 10 Dia, 3 Face, 4 DP, New 70s REF#103 FELLOWS #10-2, 10 Dia, 4 Face, 4 DP REF#103 FELLOWS #20-4, 20 Dia, 4 Face, 4 DP, 70s REF#103 MAAG #SH-100/140, 57 Dia., 12.6 Face, 2 DP, Internal Attachment REF#103 FELLOWS #3-1,/3GS, 3 Max Dia, 1 Face, Pinion Supp, High Precision REF#103 FELLOWS #48-6 INTERNAL GEAR SHAPER ONLY,0-72"OD,6" Face REF#103 LORENZ #SJV00, 7 Dia, 2 Face, 50s REF#103 MAAG #SH-100K 47/12.6/1.7 60s Internal Attachment REF#103 MAAG #SH-150, 57" Dia.12.6" Face REF#103 PFAUTER #SH-180 Shobber 7" capacity hobbing, 9.45" cap REF#103 FELLOWS #36-6 Max Dia 36 6 Face, 3 DP REF#103

FELLOWS #HORZ Z SHAPER, 10 x 6 Dia 27.6 Face 8.5 REF#103 MAAG #SH-75C, 30/8/2.5/52 REF#103 MAAG #SH-600, 235 Dia 36, 1DP REF#103 FELLOWS #4GS & 4AGS, 6 Dia, 2 Face, 4DP, 68, Ref.# Several REF#103 TOS OH-6, Dia 19.7 REF#103 FELLOWS #624A, 18 Max Dia, 5 Face REF#103 FELLOWS #7, #7A, #715,# 75A, #715, #725A, 7 Dia, 0-12 Risers, Several Avail REF#103 MAAG #SH-180-300 , Max Dia 118/ 16.9 Face REF#103 MAAG #SH-350/500, Max Dia 197 REF#103 MICHIGAN #18106 SHEAR-SPEED GEAR SHAPER,14" Dia, 6"Face REF#103 FELLOWS Model Z Shaper, 5" Stroke, 50s REF#103 STAEHELY SHS-605, Gear Shaper REF#103 FELLOWS #6, #6A, #61S, From 18-35 Dia, 0-12 Risers REF#103 FELLOWS #8AGS Vertical Gear Shaper, 8 Dia, 2 Face, 6-7 DP REF#103 TOS OHA50 CNC 5 20 Dia 5 Face REF#105 Fellows 36-6 Shaper (2) 12.5" Risers 6" Stroke Mint YR 1969 id 3616 REF#106 GEar DEBUrrinG/CHaMFErinG/PointinG CROSS #50 Gear Tooth Chamferer, 18 Dia, Single Spindle REF#103 CROSS #75 Gear Tooth Chamferer, 10 Dia, 10 Face, 52 REF#103 REDIN #18, 28 Dia, 2, 3, 4 Spindle, Deburrer/Chamfer, PLCs, Tilt Table REF#103 REDIN #20D, 20 Dia, Twin Spindle, Deburrer/Chamfer REF#103 SAMPUTENSILI #SCT-3, Chamf/Deburrer, 14 Dia, 5 Face, 82 REF#103 SAMPUTENSILI #SM2TA Gear Chamfering Mach, 10 Max Dia, (3) New 96 REF#103 REDIN #24 CNC Dia 4 Setup Gear Deburring REF#103 CROSS #60 Gear Tooth Chamferer, 10 Dia, Single Spindle REF#103 FELLOWS #100-180/60 CNC Max Dia 180, Single Spindle REF#103 CIMTEC #50 Finisher REF#103 RPM #GC-500 CNC 20 Dia, Single Spindle REF#103 CROSS #54 Gear Deburrer, 30 Dia, 18 Face REF#103 RED RING #24 Twin Spindle Dia 4 REF#103 CROSS #55 Gear Deburrer, 18 Dia, 1.5 Spindle REF#103 GLEASON GTR-250 VG CNC 5-Axis REF#103 GRATOMAT #300L REF#103 GEar HonErS Fassler #K-400 CNC Hone 16" Dia REF#103 Fassler K-400A CNC Hone 16 Dia REF#103 Kapp #CX120 Coroning 4.7 Dia REF#103 Red Ring GHD-12, 12 Dia, 5.5 Stroke REF#103 Red Ring GHG, 12 Dia, 5.5 Stroke REF#103 Kapp #VAC65 Coroning 10 Dia REF#103 GEar SHaVErS Red Ring #GCX-24" Shaver, 24 Dia, 33 Stroke REF#103 Red Ring #GCU-12, 12 Dia, 5 Stroke REF#103 Red Ring #GCU-8 Shaver. 8 Dia REF#103 Red Ring #GCY-12, 12 Dia, 5 Stroke REF#103 Red Ring GCI 24, 12.75 Dia, 5 Stroke REF#103 Nachi Raso CNC Shaver, 3-Axis REF#103 Michigan #873-24A, 24 Dia, 15 Face, 2 DP REF#103 GEar GEnEratorS, StraiGHt BEVEL GLEASON #37 Str. Bevel Planer, 6 Dia REF#103 GLEASON #54 Str, Bevel Planer, 60 Dia REF#103 GLEASON #496 Straight.& Spiral. 7.5 Dia REF#103 GLEASON 14, Coniflex Straight Bevel REF#103 GLEASON 24A Straight Bevel REF#103 GLEASON 725-Revacycle, 6 Dia REF#103 GLEASON 726-Revacycle, 5 Dia REF#103 GLEASON 2A, 16 Cone REF#103 GLEASON #116, 9 Cone, 2.75 Face REF#103 GLEASON #104 w/Helical Motion, Coniflex, Straight Bevel REF#103 GEar GEnEratorS, SPiraL BEVEL (HYPoiD) GLEASON #645 Hypoid Generators REF#103 GEar GrinDErS CnC HOGLUND, Model #264, CNC Internal Gear Grinder REF#103 KAPP #VAS-482 CNC GEAR GRINDER, 11.8" SWING DIA REF#103 GLEASON Phoenix 200G Hypoid Grinder CNC REF#103 REISHAUER RZ-801 CNC, 31.4 Dia REF#103 NILES ZSTZ 06-800 CNC, 31.5 Dia, 11 Face REF#103 NILES ZSTZ 08-800 CNC, 32 Dia, 11 Face REF#103 RED RING #SF-500 CNC Int/Ext, 26 Dia, REF#103 GLEASON/TAG 400 CNC, 16 Dia REF#103

HOLFER PROMAT 200 , 7.87 Dia CNC Gear Grinder REF#103 GEar GrinDErS #27, #137, and #463 Gleason Hypoid Spiral Bevel gear grinder generating Cams (2 full sets) REF#102 Springfield Vertical Grinder, 62" Table, #62AR/2CS, 3.5A Rail Type, 70" Swing REF#102 REISHAUER ZA, Gear Grinder, 13" Dia, 6" Face, Strait & Helix REF#103 RED RING #SGJ-18, 18 Dia., 9 Face, Internal Attachment, New 78 REF#103 DETROIT Gear Grinder #GGI-16x3A, Internal Gear Grinding, 16" OD REF#103 MAAG SD-32-X REF#103 GLEASON #463, 15 Dia REF#103 HOFLER BHS H1603-2000, 78.7 Dia REF#103 NILES ZSZT-3500, 139 Dia REF#103 KAPP VAS #331, Gear Grinder REF#103 NILES ZSTZ-1250/5000 49.2Dia REF#103 GEar raCK MiLLErS/SHaPErS MIKRON #134 Rack Shaper, 17.4" Length, 1.1" Width, 16.9 DP REF#103 SYKES VR-72 Vert Rack Shaper, 72" Cut Length, 4DP, 4" Stroke, 80 REF#103 SYKES VR-60 Vert Rack Shaper, 60 Cut Length, 4DP, Stroke 4 REF#103 GEar tHrEaD & WorM, MiLLErS/GrinDErS LEES BRADNER #HT 12x54, Dia 12 /54 REF#103 MOREY-SHIELDS THREAD MILLER, Dia 12 REF#103 BARBER-COLMAN #10-40, 10" Dia., 40" Length, 4 DP REF#103 EXCELLO #31L, External Thread Grinder, 5" OD, 20" Grind Length REF#103 EXCELLO #33 Thread Grinder 6 Dia 18 Length REF#103 EXCELLO #35 and #35L Thread Grinder, 84" Between Centers REF#103 EXCELLO #39 Int. Thread Grinder, 9.5" Max Dia., 10" Max. Swing REF#103 HURTH #KF-33A Multi-Purpose Auto-Milling Machine 88 REF#103 LEES BRADNER #HT12x102, Extra Large Capacity REF#103 J&L AUTOMATIC THREAD GRINDER, 6" X 36", 38 REF#103 LEES BRADNER #HT 12"x 144" Thread Mill, 12" Dia, REF#103 WALDRICH COBURG WHIRLING, 3 Dia, 118 Length REF#103 LEES BRADNER # LT 8 x 24 8 Dia REF#103 HOLROYD 5A 24.8 Dia REF#103 HECKERT WMW #ZFWVG REF#103 LEES BRADBER WORM MILLER REF#103 GEar tEStErS/CHECKErS (incl CnC) FELLOWS (1) RL-600 Roll Tester s/n 35814 REF#102 FELLOWS (1) 24H Lead Checker s/n 32289 REF#102 GLEASON (1) #14 Tester s/n 31907 REF#102 GLEASON (1) #6 Tester s/n 19316 REF#102 FELLOWS (1) 20 M Roller Checker REF#102 FELLOWS (1) 20 M w/ 30 Swing Roller Checker REF#102 FELLOWS (1) #8 Micaodex s/n 36279 REF#102 David Brown #24 Worm Tester REF#103 Fellows 12H Gear Tester REF#103 Fellows #12M Gear Tester REF#103 Fellows 20M Gear Tester REF#103 Felows #24 Involute Measuring Instrument REF#103 Gleason #4, #6, #13 and #17 Testers REF#103 Hofler EMZ-2602 Int/Ext Gear Tester 102 REF#103 Klingelnberg #PFSU-1200 Gear Tester REF#103 Klingelnberg #PFSU-1600 Gear Tester-2001 REF#103 Klingelnberg PWF-250 Tester REF#103 Kapp Hob Checker WM 410 REF#103 Maag #ES-430 Gear Tester REF#103 Maag #SP-130 Lead and Involute Tester REF#103 National Broach Gear Tester GSJ-12 REF#103 Oerlikon #ST2-004 Soft Tester REF#103 Maag #SP-60- Electronic Tester REF#103 Parkson #42N Worm Gear Tester REF#103 Fellows #24H Tester REF#103 Gleason #104 Tester REF#103 Vinco Dividing Head Optical Inspection REF#103 MiSCELLanEoUS WARNER & SWAYSEY #4A M-3580 Turret Lathe, 28 1/4 Swing, 80 Centers, 12 Spindle Hole 50/25 Motors, 480/3 Phase, Year 1965 REF#101 Springfield Vertical Grinder, 62" Table, #62AR/2CS, 3.5A Rail Type, 70" Swing REF#102 GLEASON #529 Quench, 16" Diameter REF#103 VERTICAL TURNING LATHES AND MORE - Please Check Our Website To View Our Entire Inventory REF#103 TOS SU & SUS Series Conv Lathes REF#105 TOS SUA Series CNC Flat-Bed Lathes REF#105

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Danfoss Re-approved as authorized CeU provider

Danfoss VLT Drives has been re-approved by the International Association for Continuing Education and Training (IACET) as an Authorized Provider of Continuing Education Units (CEUs). The recognition period extends for five years and includes all programs offered or created during that time. Danfoss is proud of our education programs, which train more than 1,000 participants each year in all aspects of selecting, installation, commissioning, and servicing Danfoss VLT Drive products so they have the competency and skills to effectively and efficiently utilize our technology to its maximum potential, says Jeff Duncan, marketing manager. Our continued partnership with IACET is a demonstration of our commitment to lifelong learning and high standards for all of our programs, and we are very pleased to maintain our relationship with such a prestigious organization as well as an elite group of organizations that offer excellent continuing education and training programs. We are pleased to have Danfoss continue their continuing education and training work as an Authorized Provider organization, says Karen Niles, president of IACET and director of professional development at the American Speech-Language-Hearing Association. Danfoss is one of nearly 650 organizations around the globe that have had their programs vetted by third-party experts in continuing education to ensure the highest possible standards are met. In order to achieve Authorized Provider status Danfoss completed a rigorous application process, including a review by an IACET site visitor, and successfully demonstrated adherence to the ANSI/IACET 1-2007 standard addressing the design, development, administration, and evaluation of its programs. Danfoss has pledged its continued compliance with the standard, and maintains its authorization to use the IACET name and Authorized Provider logo on promotional course material. In addition, Danfoss is now linked to the IACET Web site and is recognized as offering the highest quality continuing education and training programs. The International Association for Continuing Education and Training (IACET) is a non-profit association dedicated to quality continuing education and training programs. IACET is the only standard-setting organization approved by the American National Standards Institute (ANSI) for continuing education and training. The ANSI/IACET 1-2007 standard is the core of thousands of educational programs worldwide. Learn more at [www.iacet.org]. Danfoss is a leading manufacturer of precision mechanical and electrical components, with locations in more than 120 countries. In addition to setting the standard for highperformance quality variable frequency drives, Danfoss meets the needs of its customers through its EnVisioneering partnerships, focusing on developing new technologies for sustainable business growth through engineering innovation, energy efficiency, and environmental responsibility. Go online to [www.danfossdrives.com].

Beaver aerospace & Defense receives Boeing performance excellence award

Beaver Aerospace & Defense has received a 2010 Boeing Performance Excellence Award. The Boeing Company issues the award annually to recognize suppliers who have achieved superior performance. Beaver maintained a Gold composite performance rating for each month of the 12-month performance period, from Oct. 1, 2009 to Sept. 30, 2010. This year Boeing recognized 558 suppliers who achieved either a Gold or Silver level Boeing Performance Excellence Award. Beaver is one of only 141 suppliers to receive the Gold level of recognition. Beaver Aerospace & Defense is honored to receive the Gold-Level Boeing Performance Excellence Award, says Jason Ratcliffe, general manager. Beaver takes great pride in being recognized by a world-class company like Boeing and looks forward to continued success in the future. Beaver supplies ball splines to Boeing for the CH-47 Chinook helicopter, as well as a camera deployment actuator for the P-8 military aircraft. Beavers award-winning actuation systems and components (e.g., ball screws and gears) are custom designed to fit virtually

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mArKet
manufacturing excellence through quality, integration, materials, maintenance, education, and speed.

PLACE

We Manufacture Broaches & related tooling for any Broach Machine

Sharpening or reconditioning alSo production Broaching
We Weld Broken & Chipped Broaches

Apollo Broach, Inc.

www.apollobroach.com
Services: Round Broach:
Broach Design O.D./I.D. Grinding Lathe Standard Round Cross Hole

Spline Development
Involute Inverted Serration Straight Angular

Re-sharpening & Reconditioning:

We offer immediate reconditioning or rebuild of worn or broken broaches.

Surface Grinding:

Broach house Mfg., inc.

We Have Used Broaches In Stock
11383 Route 166 Marion, Il 62959 618-993-3530 Fax:618-997-9158 e-mail: broachhouse@yahoo.com
technical solutions aerospace and automotive applications

Flat Inserts Angular Form Inserts Squares Hexagon Key Ways Form Inserts Serration Form Inserts DD Form Standard Key Ways

Polishing High Speed Welding 24-Hour Emergency Turnaround Service:

We will provide the best possible delivery, quality and service for our customers.

Email: apollobroach@att.net Phone: (734) 467-5750 39001 Webb Ct. Westland, MI 48185 Fax: (734) 467-5753

LAWLER GEAR CORP.

l e e s s u M M i t , M i s s O u R i

Multiple start Gear Grinding Wheels

lower grinding forces new abrasive blends & bonds lower grinding temperatures increased porosity for higher stock removal

(from singles to production & reverse-engineering services)

SPUR - HELICAL - SPLINE - WORM - BEVEL - RACK

Gear Manufacturing

Gear honing benefits

Flank correction Reduced operating noise longer service life correction for distortion from hardening process

Gear Hobbing Gear Shaping Gear Rack Sprockets Broaching CNC Turning CNC Milling Automatic Sawing

HANDFUL

OR A

TRUCKLOAD!

LAWLER GEAR CORP.

Hermes Abrasives, Ltd.
1320 S.E. Hamblen Road Lees Summit, MO 64081
524 Viking drive Virginia beach, Va 23452 Po box 2389 Virginia beach, Va 23450 toll free phone: 800.464.8314 toll free fax: 800.243.7637

Toll Free: 800-346-3038

Missouri: 816-525-0002 Fax: 816-525-1113

JUNE 2011

65

any application. And, to top it off, Beaver is the industry leader in on-time delivery, with current performance exceeding 99.8 percent. Performance excellence is fundamental to the success of both our companies, says Ron Shelley, vice president of supplier management for Boeing Defense, Space & Security. We extend our sincere congratulations to the employees of Beaver Aerospace & Defense for demonstrating their dedication to the high performance standards necessary to meet customer expectations and remain competitive in the global economy. Beaver Aerospace & Defense, Inc.a subsidiary of Phillips Service Industries, Inc.is a global leader in the design and manufacturing of unique and broad-range actuation technologies for the aerospace and defense industries, serving commercial and military markets, as well as the alternative energy industry. Its award-winning actuation systems and components (e.g. ball screws, gears and splines) are custom designed to fit virtually any application, and can be found on some of the most advanced aircraft, missile applications, and mission-critical space exploration systems in the world. Beaver also provides expert repair, overhaul, and testing services for all electromechanical actuators and ball screws. For more information visit [www.beaver-online.com].

Mitutoyo Corporation is the worlds largest provider of measurement and inspection solutions offering the most complete selection of machines, sensors, systems and services with a line encompassing CMMs (Coordinate Measuring Machines), vision, form and finish measuring machines as well as precision tools and instruments, and metrology data management software. Mitutoyos nationwide network provides application, calibration, service, repair and educational programs. Call (630) 820-9666, e-mail info@mitutoyo.com, or visit [www.mitutoyo.com].

California Brazing awarded aS9100 accreditation

California Brazing is pleased to announce its official accreditation to the AS9100 international aerospace quality standard. The scope of this accreditation includes heat treating, machining, brazing, and contract manufacturing. This certification reflects California Brazings ongoing commitment to continuous improvement, along with its desire to meet and exceed the increasingly stringent industry requirements for aerospace related products and services. The AS9100 certification will strengthen the companys competitive position in the aerospace market, and it will also benefit their non-aerospace customers in the semiconductor, medical, and energy management markets. California Brazing is a manufacturer of critical components found at the heart of their customers complex products. Nadcap aerospace brazing accreditationAWS C3.7 and AWS C3.6is scheduled for June of 2011. For more information contact Jeff Ager, general manager, at jeffa@ californiabrazing.com. Visit online at [www.californiabrazing.com].

StRato-apex CMM from Mitutoyo

The new STRATO-Apex coordinate measuring machine from Mitutoyo America Corporation combines an advanced structure with newly developed high-performance control and scanning technologies. The result is faster drive speeds, higher acceleration, and a CMM that is a productivity leader in the 1m class. The extremely rigid STRATO-Apex CMM structure incorporates vibration-dampening, auto-leveling air springs and the newest compensation technology to support acceleration of 2,598mm/s2 (3D), 0.23g (3D) and measuring scan speeds up to 3mm/s. The STRATO-Apex features digital servo system control loops for position, speed, and current. This makes it easy to implement various types of control algorithms. Additionally, the digital servo system has a wide dynamic range and is highly resistant to drift over time. The controller is located outside the main unit to mitigate the effect of generated heat. The ultra-high accuracy measurement units installed on each axis of the STRATO-Apex consist of high-performance reflective linear encoders that utilize ultra-high precision crystallized glass scales, which exhibit virtually no thermal expansion (coefficient of linear expansion of 0.01 x 10-5/C). The available software options enable the STRATO-Apex to tackle a wide variety of measurement applications. Software packages include GEOPAK, a high-functionality general-purpose measurement program which is at the heart of MCOSMOS (Mitutoyo Controlled Open System for Modular Operation Support) software. MCOSMOS supports virtually every CAD format while providing routines for in-line measurement, data feedback, and process management. Additional software supported includes: CAT1000S for freeform surface evaluation; CAT1000P, an offline teaching program; SCANPAK, for contour measurement; and a wide variety of programs supporting laser and vision probes. Additionally, STRATO-Apex supports MeasurLink STATMeasure Plus, Mitutoyos proprietary statistical-processing and process-control program. MeasurLink STATMeasure Plus performs statistical analysis and provides real-time display of measurement results for SPC applications. The program can also be linked to a higher-level network environment for enterprise-wide functionality.

New product Catalog from emerson Bearing

Catering to OEM (original equipment manufacturers) and MRO (maintenance, repair, and operations) markets throughout the world, Emerson Bearing has recently announced the availability of a new product catalog. Due to demand, Emerson Bearing has converted its extensive online product catalog into a traditional 210-page print catalog. The comprehensive print catalog better suits a number of Emersons bearing clients who may not have easy access to a computer, or who simply prefer the print catalog over the online catalog. Emerson Bearing provides solutions to a variety of industries including aggregate, concrete, mining, machine tools, electric motor repair, marine, material handling, metal processing, packaging, food processing, paper converting, printing, power generation, recreation, heavy construction, robotics, automation, transportation, wood products, wastewater treatment, pump, compressor, and oil field. The free catalog is available upon request. In a proud tradition, the same families that started the company in 1957 keep Emerson Bearing rolling by specializing in bearings for OEM and MRO markets across the country. Emerson Bearing has a staff of 22 and a 23,000 square-foot facility to provide bearings ranging in size from 3mm to tunnel-boring 15-foot-diameter giants. Emerson Bearing offers customers a one-stop shopping experience. With an online product catalog with over three-million bearings, a vast inventory of bearings, worldwide sourcing, a fixed price program, a knowledgeable staff dedicated to delivering, same day shipping and 24/7 service, Emerson Bearing has become the leading provider of bearings to OEM and MRO markets in the United States. For more information on the company and its line of products call (800) 225-4587, e-mail info@ emersonbearing.com, or visit [www.emersonbearing.com].

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ADvERTISER iNDeX
COMPANY NAME .............. PAGE NO.
Allen Adams Shaper Services ..................................................65 Apollo Broach Inc ....................................................................65 AWEA 2011 ............................................................................55 Banyan Global Technologies ....................................................50 Bourn & Koch .........................................................................67 Broach House Manufacturing ..................................................65 Circle Gear and Machine .........................................................43 Clarke Gear Co .......................................................................50 Cole Manufacturing Systems Inc..............................................65 Delta Gear ..............................................................................18 DT Technologies sa .................................................................46 Engineered Tools Corporation (ETC) ...................................34-35 Forest City Gear ......................................................................16 Gear Expo 2011 ......................................................................47 Gear Manufacturing Inc ...................................................... 10,64 Gear Solutions Online ..............................................................52 Gleason Corporation ...............................................................31 Hanik Corporation ...................................................................67 Hermes Abrasives Ltd .............................................................65 Hilco Industrial LLC .................................................................63 Ingersoll Cutting Tools .............................................. 11,13,15,17 Innovative Rack & Gear Co ......................................................64 Iosso Metal Processes ............................................................51 JLM Systems Ltd ....................................................................37 KAPP Technologies ............................................................... IFC KISSsoft USA LLC ..................................................................12 Klingelnberg GmbH ...................................................................2 Lawler Gear Corp ....................................................................65 Micro Gear ..............................................................................46 Micro Surface Corp .................................................................12 Mitsubishi Heavy Industries America Inc ................................. BC New England Gear ....................................................................7 Niagara Gear...........................................................................14 Overton Chicago Gear .............................................................65 Precision Gage Company ........................................................32 Process Equipment .................................................................44 Proto Manufacturing Ltd ..........................................................58 R P Machine Enterprises Inc ....................................................60 Raycar Gear & Machine Co .....................................................44 Repair Parts Inc ......................................................................43 Riverside Spline & Gear Inc ..................................................9,38 Russell Holbrook & Henderson ................................................36 Sandvick Coromant ............................................................... IBC STD Gear ................................................................................51 Stor-Loc..................................................................................45 The Broach Masters ..................................................................4 The Company Corporation ......................................................64 TMFM LLC ..............................................................................32 Toolink Engineering ...................................................................1
www.hanikcorp.com

CORPORATION

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Q&a
PRESIDENT

matt MonDek
COTTA TRANSMISSION COMPANy

GS: Cotta Transmission has been in business for more than a century. Could you tell us a little about its history and areas of expertise? MM: Id be glad to. Charles Cotta was an engineer and inventor who established the company in the early 1900s, right when Henry Fords automobile assembly line was revolutionizing American manufacturing. Cotta introduced what was known as the constant-mesh shifting transmission, which he was soon supplying to the emerging automobile and truck industry. In the late forties Cotta began a shift to industrial, heavy duty, and construction products, and in the sixties added a line of highspeed gearboxes. Today Cotta is a trusted manufacturer of precision-engineered premium transmissions in both stationary and mobile applications such as mining, drilling, industrial, and marine. We are a niche company, and we design everything we make and make everything we design. One of our core competencies is our unique ability to transform our customers concepts, regardless of the application, into a value-adding component they can incorporate into the product theyre manufacturing. Cotta Transmission continues to be known for value-engineered solutions, and were here to help our customers meet the demands of their markets.

GS: How did you come to join the company? MM: After earning my bachelors degree in mechanical engineering from the University of Wisconsin-Madison I went to work for the Outboard Marine Corporation, where I worked in the design department on the Evinrude and Johnson lines. I was with OMC for nearly 24 years before they were forced to file Chapter 7. While there Id enrolled in the MBA program at Lake Forest Graduate School of Management, graduating in 1991, and Id studied with a gentleman who eventually became the president of Cotta Transmission. He was looking for a vice president of operations and engineering, so he brought me on in 2000, just before OMC filed for bankruptcy. Over the years Id made a point of exposing myself to as many different areas as possible, working in design engineering, purchasing, program management, and strategic sourcing, among other positions. So that experience, in addition to all that Id learned while working toward my MBA, positioned me well when the presidents position opened up. That was in 2003, so Ive been with the company for 11 years and in this position for the past eight years. GS: Congratulations on being named chairman of the board of the American Gear Manufacturers Association. What are your plans for the coming years? MM: Thank you. Its very exciting, and Im honored to have the opportunity to serve the industry in this capacity. Im going to do everything I can to help foster and promote the excellent programs that are

already in place, especially those involving online training and education. Theres such a need to make learning opportunities readily available and easy to access, so we will continue building on the great foundation thats already been laid by the AGMA staff. Another area involves recognizing the changing needs of the industry and its membership. We have members located all around the world, of course, so we need to be aware of their needs, and also those of the younger generation just beginning their careers in the industry. We

AGMA members are an awesome group of people, and youll make friends you can rely on throughout your life and career.
need their energy and input, and its up to us to make a good case for why they should join the AGMA in addition to their primary responsibilities and concerns. My personal conviction is that membership provides opportunities to meet and learn from industry leaders and to help develop the standards that govern our work. More than anything, though, AGMA members are just an awesome group of people, and youll make friends you can rely on throughout your life and career. So my advice to anyone whos considering joining is to go for it, because I can promise that youll be glad you did!

TO LEARN MORE:
Call (608) 368-5600, e-mail sales@cotta.com, or go to [www.cotta.com]. Also visit [www.agma.org].

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