Frozen gears (Замороженные шестерни) (1993) PDF

GEAR
TECHNOLOGY
THE JOURNAL OF GEAR MANUFACTURING
SPECIAL FOCUS ON HEAT TREATING

CONTROLLING THE CARBURIZING PROCESS FOR TOP QUALITY GEARS
DUAL FREQUENCY INDUCTION HARDENING
FROZEN GEARS
SURFACE MEASUREMENT TECHNOLOGY
INTRODUCTION TO WORM GEARS
EXPORTING - GETTING STARTED
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C IR C L E A-1 on R E A D E R R E P L Y C A R D
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u m itea rartnersmp
1351 Windsor Road. P.O. Box 2950. Loves Park IL 61132-2950 USA
Telephone 815-877-8900 FAX 815X77-0264
CIRCLE A-2 on REAOER REPLY CARO
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Phone (216) 642-0230. FAX (216) 642-0231.
C IRCLE A-7 on R E A D E R R EP LY CARO
CONTENTS
M A R C H /A P R IL 1993
FEATURES
Controlling the Carburizing Process for Top Quality Gears
R o y F. Ke r n
Kern Engineering Co., Peoria. IL.....................................................................
16
Dual Frequency Induction Gear Hardening

J o h n M. S t o r m <5 M i c h a e l R. C h a p l i n
Contour Hardening. Inc.. Indianapolis, IN........................................................
22
Frozen Gears
P e t e P a u l in
300 Below. Inc.. Decatur, IL...............................................................................
26
Improving Gear Manufacturing Quality W ith

Surface Measurem ent Technology
Mike Moy er
Rank, Taylor. Hobson, Inc.. Dcs Plaines, IL........................................................
30
SPECIAL FEATURES
Cover photo courtesy of Fluxtrol
Manufacturing. Troy, MI.
Gear Fundamentals
Introduction to Worm Gears
J a m e s K. S i m o n e l l i
JKS & Associates. Brecksville. OH......................................................................
34
D EPA R TM EN TS
Publisher's Page
Little Things Mean A Lot.....................................................................................
Advertiser Index
Find the products and services you need.........................................................
Shop Floor
Gear M aterial Quality: How To Judge ItPitting: How To Prevent It
Do n M c V i t t i e .
Gear Engineers, Inc., Seattle, WA..................................................................
11
M anagem ent Matters:

Getting Started In Exporting
Nancy Bartels
Interview with Rick Norment of Norment & Associates.
First in a 4-part series on exporting.................................................................
Classifieds
Products, services, and information vou can use.................................................
Calendar
Events of interest....................................................................................................
41
46
48
^ hTohnoon
HIM uirr \ SI 11.11

FIXE 00*101 ABTIFAPTX
bridles buckles horsehair
E D IT O R IA L
bits books belts bolos
Publisher & Editor-in-Chicf

Michael Goldstein
chaps
western collectables T^T
GEAR TEC H N O LO G Y
it
spurs saddles
IPI'BAISALS
Associate Publisher & Managing Editor

Peg Short
9929 Venice Blvd.

Los Angeles. CA 90034
Senior Editor Nancy Bartels
CUO) 202*3010 III APPOINTMENT

FAI (1 10 )2 02 1 (40
Technical Editors
Robert Errichello
William L. Janninck
Don McVittle
Robert K. Smith
CIRCLE A-4 on REAOER REPLY CARD
A RT
Art Director Jean Sykes
An Director Jennifer Goland
M A R K ETIN G
Sharpens both bodies with integral blades

and stick blades
Advertising Sales Manager Patricia Flam

Sales Coordinator Donna-Marie Weir
C IR C U L A T IO N
Administrative Coordinator
Deborah Donigian
Circulation Assistant
Janice Jackson
RA N D A LL PU B LISH IN G STA FF
President Michael Goldstein
Vice President Richard Goldstein
Vice President/General Manager Peg Short
Controller Patrick Nash
Accounting l.aura Kinnane
Art Consultant Marsha Goldstein
RA N D A LL PU B LISH IN G , IN C.
CHECH THESE
FEATURES:
Accuracy - All grinding
operations completed in a
single step.
/ Full Probing Capabilities For both part and wheel

location.
Rapid Setup or Changeover Bodies to blades, roughing to

finishing, other diameters
/ CBN W heel- For better

surface integrity and finish,
longer tool life.
T h e s e features result In u n p re ce d e n te d productivity.
CONTACT US FOR FULL DETAILS
27,
ELK RAPIDS EN G IN EERIN G

Subsidiary ol Star Cutter Company
210 Industrial Park Drive P.O. Box 728 Elk Rapids. Ml 49629
Phone 616/264-5661 Fax 616/264-5663
C IR C L E A -5 on R E A D E R R E P L Y C A R D
GEAR
TE C H N O L O O V
1425 Lunt Avenue

P.O. Box 1426
Elk Grove Village. IL 60007
(708) 437-6604 Phone
(708) 437-6618 Fax
VOL. 10, NO. 2
GEAR TECHNOLOGY. The journal of t.ra r M .aafa. luring
I IS S N 0 7 4 .t4 * * a > It p ublished b im onthly bv R andall P u blishing.
Inc . 1435 L u w A v en a e. P O B o* 1 4 2 6 . Elk G ro v e V illa g e . IL
60007
S u b scrip tion rale* are 5 4 0 0 0 in the U J . . 5 5 0 .0 0 ta
C an ada. 5 5 3 .0 0 in a ll other co u n tr ies S e c o n d -C la ss p o sta g e paid
ai A r lin g to n H eigh t*. IL. and at a d d ition al m a ilin g o f f ic e
Randall Publishing m ike* e w y efTon 10 e n u r e (hat the processes
described m G tm r
conform io sound engineering practice
The Publisher cannot be held responsible or liable foe injuries sustained or
any direct o in d im i. special, nwi sequent ial. or other dam ages o f any kwd
or nature whatsoever resulting from follow in g (he procedures described
Randall Publishing is am responsible for ihc content of. claim*
made, or opinions espressed in adseniscm ents or other printed matter
in the publication
Postm aster Send address changes to G E A R TEC H N O LO G Y . The
Journal o f O ear M anufacturing. 1425 l.unt A venue P .O B o s 1426.
Elk G rove V illa g e. IL. 6 0 0 0 ?
C ontents copyrighted by R A N D A L L P U B L ISH IN G , IN C .. 1993
A n k le s appearing in GF.AR TECHNOLOGY m ay not be reproduced
tn w h ole or in pan w ithout the e sp r e ss perm istion o f the publisher or
the author
GM1-KANZAKI
DOES IT
BETTER
he concentricity ol these four
gears in relation to each other
Why? Because
is unmatched since the

operation is completed on a
GMI-Kanzaki
CNC Machine, consecutively,
World Class
with the same set up. Everyone
CNC Shaving
else has to run each gear
Machines
through as individual, expensive
feature a turret
type cutter
shaving operations, handling

the parts as many as four times.
GMI-Kanzaki does it bener
system to shave
with heavy duty construction
as many as 4
for increased stability and
cluster gears
consecutively.
rigidity You'll appreciate the

resulting increases in tool life
and superior surface finish.
Overall, the outstanding
increase in quality as a result of
consecutive operations and
heavy duty construction will
have a dramatic impact on
profitability. It all adds up to a
greatly improved bottom line.
The GST-400-CNC5
is a horizontal gear shaving
machine with a turret type
ATI 4-cutter system. This enables the
GST-400-CNC5 to shave up to 4 different gears
consecutively with one chucking load
GMI-Kanzaki gives you the edge to emerge as a major player in a world economy.
GMI-Kanzaki
6708 Ivandale Rd
P.O. Box 31038
Independence, OH 44131
Phone (216) 642-0230 FAX (216) 642-0231
CIRCLE A-14 on READER REPLY CARD
GMI-KANZAKI
This is how America gears

up for quality
Most of the universal CNC gear inspection systems sold in the
U.S. come from M&M Precision Systems. More than all our
competitors combined.
Why?
Because M&M systems give you the strongest competitive
advantage
How?
Consider these three examples:
Easier inspection
Once your part is on an M&M machine, the computer screen
prompts you to enter specifications. Then you tell it what fea
tures you want to analyze, and the machine inspects the part
The next time, all you do is enter the part number. It's that easy.
M ore capability
You get true |not just theoretical) index, lead and involute testing
using interactive Generative Metrology techniques. The Inspec
tion of blanks and cutting tools as well as gears. SPC and cutting
tool software And the ability to inspect gear surface finish, spiral
bevel and hypoid gears, worms, involute scrolls, and male/female
helical rotor vanes
Better technical support and service

You'll get a choice of standard or custom engineered packages
with specific application software And M&M programs are
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or cultural differences So you'll avoid clashes between your
American results approach and other countries' process
approach.
,
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Get all the fast, free facts in the 12-page M & M OC Gear
Analyzers brochure Circle the number below Call 513/
859-8273. Or Fax 513/859-4452 today
And put your quality in gear.
M & M P R E C IS IO N
SYSTE M S
AN ACM ECLEVELAN D COMPANY
Little Things M G 3 I1
" G o d is in the details,
says the phil
A Lot
make all the difference.
osopher. W hat he meant was that on the scale
Likewise, while not every reader will have
o f the universe, it's not ju st the galaxies, the
occasion to use the technology discussed in our
planets, the m ountain ranges, or the m ajor
Gear Fundam entals feature. Introduction to
rivers that are im portant. So are the subatom ic
Worm G earing," as the author points out, care
particles and the genes. I t's the little things
ful attention to detail can make this old fash

ioned" gear system just the right one for par
that make all the difference.

T hats true on other scales as well. Its
ticular applications.
certainly true in magazine production, and. I
Not all the de
believe, its equally true in gear m anufactur
tails that need atten
ing. The small stuff docs matter. Its not enough
tion relate to what
to have a good design. The right materials are
happens in the de
important as well. So is the proper handling of
sign offices or on
those materials.
the shop floor. In
Even a good product alone is not enough to
to d a y s econom y,
make a successful business. The financial plan
what happens across
ning. the labor/management relations, the adver
the globe may have
tising and marketing, all need to be carefully
as much impact on
managed to make any business successful.
y o u r b u sin e ss as
In this issue of Gear Technology we are fo
PUBLISHER'S PAGE
w hat h a p p e n s in
cusing on some of the little things that are
your
important to your gear business. Heat treating,
companies thinking
p la n t.
For
for example, is not the whole story in gear manu
of becoming part of
facturing. but failure in this small area can mean
this global m arket,
all your hard work and careful planning in design
we have included
and production will come to naught. In heat
the first article in a
treating, its what you dont sec. what happens
series on exporting.
beneath the surface on the molecular level, that
T his story covers
tf It
makes the difference between a good and a bad
the basics o f get
gear. Therefore, we have included three articles
ting started: what do you need to do, know, and
on heat treating,
think about - the details to be considered before
covering some
, . . .
ot the basics as
making this important business move.
h ow ever trifling,
w ell
new
losophy. science, or gear m anufacturing. While
is too minute... "
technologies, to
its true that one can run the risk of m issing the
\r
. . . n o circum stance,
-O liv e r G o ld sm ith
as
The little things do matter, whether in phi
help you look
forest because o f the trees, one can also forget
more closely at
that without the tw igs, leaves, roots and sub
this im portant
soil, th eres no forest at all.
detail o f the gear manufacturing process.

Gear testing is also not the whole story on
gear quality, but it too is an im portant detail, so
we have included an article on advances in
surface measurement technology. Again, in gear
Michael Goldstein
testing, accuracy in terms o f m illim eters can
Publisher/Editor-in-Chicf
G e a r
T e c h n o l o g y
R a p i d
R e a d e r
F a x
GO AHEAD
F o r m
MAKE OUR DAY

ANSWER SOME MORE
NEW & EXCITING
Q U E S T I O N S
TELL US WHAT YOU REALLY THINK.
Tell us what you liked - and what you didnt - about this issue of GEAR TECHNOLOGY. We love the compliments, and we can
take the criticism. Knowing how you feel about what we do will help us make GEAR TECHNOLOGY the best it can be. Please
take a few minutes to fill out the attached form and fax it to us at (708) 437-6618.
My company i s .
My name is_
T ell us how you read and use GEAR TE C H N O LO G Y .
1. In the last 12 months, which of the following actions have you taken as a
result of reading an article or column in Gear Technology. (Please check all that apply.)
routed item to others discussed item with others copied/reprinted item for others filed item for future reference
sought further information (from magazine, author, etc.)
no action take other action:_______________________
2. In the last 12 months, which of the following actions have you taken as a result of seeing
advertisements in Gear Technology?
discussed ad with others passed ad along to others filed ad for future reference
contacted manufacturer/supplier for more information wrote advertiser directly phoned advertiser directly
placed order for advertised product other action:________________________
no action taken
3. Which of the following industry-related publications do you personally receive under your own name? (Check all that apply.)
GEAR TECHNOLOGY American Machinist Machine Design Power & Transmission Design
Cutting Tool Engineering Others (Please list.)______________________________________________________________
4. Which do you read regularly, that is, at least 3 of 4 issues?
(Check all that apply.)
GEAR TECHNOLOGY American Machinist
Machine Design Power & Transmission Design
5. Which one publication, including GEAR TECHNOLOGY, do you find most useful in your work? (Please check only one.)
GEAR TECHNOLOGY
J American Machinist
Machine Design Power & Transmission Design
A bout G EAR T E C H N O L O G Y . ..PLEASE
RATE THIS ISSUE. CHECK THE BOX THAT APPLIES.
Features:
Controlling the Carburizing Process in Gears

Dual Frequency Induction Gear Hardening
Frozen Gears
Improving Gear Quality With
Surface Texture Measurement
Gear Fundamentals
Introduction to Worm Gears
Excellent
Good
A verage
P oor
Haven' t
a
a
a
a
a
a
a
a
Regular Columns:
Shop Floor
Calendar
Management Matters
Ad Index
Publisher's Page
PLEASE FAX THIS FORM TO US AT (708) 437-6618 OR MAIL IT TO P. 0. BOX 1426. ELK GROVE VILLAGE, ILLINOIS. U.S.A. 60009.
TH A N K S FOR YO UR HELP.
GEAR
TEC H N O L O G Y
The only trade show devoted

solely to the gearing industry
V October 10 13
Detroit, Michigan
American Gi
'ditional information:
facturers Association
King Street, Suite 201
Alexandria, VA 22314
0211 Fax:703-684-0242
CIRCLE A-15 on REAOER REPLY CARD
ADVERTISERS INDEX
Ajax Magncthcrmic Corp.
American Gear Manufacturers Association
American Pfauter. L.P.
American Metal Treating Co.
Boum & Koch Machine Tool
Cincinnati Steel Treating Company
Diseng
Fairlane Gear, Inc.
GMI Fhusa
GMI Kanzaki
Guehring Automation Inc.
High Noon
ITW Heartland
James Engineering
Koepfcr America
M & M Precision
Mack Truck
Manufactured Gear & Gage, Inc.
Normac. Inc.
Pfauter-Maag Cutting Tools, L.P.
Pro-Gear Co., Inc.
Profile Engineering, Inc.
Roto Technology. Inc.
Russell, Holbrook & Henderson, Inc.
Starcut Sales, Inc.
Tocco. Inc.
Reader Service No.

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OBC
M A R C H / A P R I L
1993
FORMASTER... BUILT FOR LASTING

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Tel: (313) 349-2644 / Fax: (313) 349-1440
Gear Material Quality:

How To Judge It...
Pitting: How To Prevent It
Don McVittie
H um do we know when the g ear m ate
Too soft for the job.
rial we buy Is m etallurgical!) co rrect?
Hard enough, but the wrong crys
How can we ju d g e m aterial quality

when all g ear m aterial looks alike?
Don M cVittie replies: G ear quality
tal structure (microstructure).

Right structure, but too many nonmetallic inclusions.
has tw o parts m aterials and geom
Cracks, holes, seams, and laps.
etry. Most people find geom etry easier
Fig. 1 shows the photom icrograph
to m easure and understand, so they
o f the core material o f a failed gear
em phasize that and ignore material.
tooth. The light-colored areas are
The most accurate gear is a waste o f
blocky ferrite." They show that the
money, though, if its m aterial is weak
gear was hardened in a separate re
or brittle. Only the best m aterials w ar
heat/quench/tem per process after car-
rant the tim e and effort necessary to
burizing and cooling, and that it w asn't
make an accurate gear.
thoroughly reheated before quench
What makes a gear material bad?
ing. Blocky ferrite is w eaker than the
SHOP FLOOR
Address your gearing ques
tions to our panel of experts.
W rite to them care of Shop
Floor, Gear Technology, P. 0.
Box 1426, Elk Grove Village,
IL 60009, or c a ll our editorial
staff at (708) 437-6604.
Don McVittie
Fig. 1
is President o f Gear Engi

neers. Inc.. Seattle. VM. He
is a past president o f AGMA
and Chairman o f the V. S.
Technical Advisory Group for
International Gear S tan
dards. He is a licensed pro
fessional engineer in the Stale
o f Washington.
desired "tem pered martensite struc

ture and is not perm itted in highly
loaded carburized gears.
H ow can b u y e r s k n o w w h a t
th e y re g ettin g ? A fter a ll, the gears
look, w eigh, and m easu re the sam e!
T he d iffe re n c e is in v is ib le , lik e
good c h a ra c te r in an in d iv id u a l, but
i t 's th ere and w ill beco m e o b v io u s
w ith tim e.
If you could look inside a wellmade carburized gear, the case micro
structure would look like the photo
shown in Fig. 2. with a uniform martensitic structure, free from defects.
Material quality is difficult to m ea
sure on a finished part because the
critical areas are inaccessible. Q u al
ity is m aintained by carefully co n tro l
ling the m anufacturing process and
checking the results each step o f the
way, from the ingot to final heat treat
ment and inspection for hardness and
surface defects.
Some purchasers have strict m ate
rial specifications and internal quality
co n tro l, allow ing them to verify the
SHOP FLOOR
quality o f the parts they buy. Others
dont have such in-house capabilities, so
they buy from vendors who have inter
nal quality controls. These qualified
vendors utilize quality standards and
inspection expertise to get the right ma
terials and processes into the gears as
theyre made. The remaining buyers take
their chances with the lowest bidder.
The American Gear Manufacturers'
Association (AGMA) develops indus
try standards for gear quality, both in
geometry and materials. The right qual
ity level can be specified by reference to
those standards, avoiding the need to
write and maintain in-house documents.
W e have a lot of p roblem s with
p ittin g in o u r shop.
W hat causes
p ittin g an d w hat is the best way to

prev en t it?
Don M cV ittie replies: Pitting can
be caused by things other than bad mateOC AR
T E C H N O L O G Y
rial. Abrasive wear and misalignment
USER-FRIENDLY
will do it. So will overload. Fig. 3 shows
DOS BASED SOFTW ARE
a gear tooth that has a good contact
EC O NO M IC ALLY PRICED
pattern, but is covered with pits. The pits
A N D SIZED
are caused by excess contact pressure:
CHECKS GEARS, SPLIN ES,
the material isn't strong enough to with
HOBS A N D M U C H MORE
stand the load being applied.
A U T O M A T IC TESTIN G
Material below the surface of the gear
so
o
m
>
tooth flows away from the load, much
J3
like bread dough under a rolling pin or the

top of a rail deforming under the pressure
of train wheels. The failure is gradual,
with particles of material flaking off into
the oil; old pits close in due to the flow of
surface material, and new pits form.
E ventually, the sm all p its jo in
into la rg e r p its, o r sp alls. T he a c c u
racy o f the tooth form is d e stro y e d ,
<
and the d y n am ic load on the teeth

increases. As the teeth get thinner and
rougher, breakage will o ccur through
SPACING/INDEX, LEAD, INVOLUTE PROFILE
o
m
the stress risers caused by the p its, as

show n in Fig. 4.
Theoretically, all gears will pit. even
at light loads. In practice, w e'd like them
Jechnology. inc.
351 FAME ROAD DAYTON. OHIO 45449

1513) 859-8503 FAX (513) 865-0656 1-800-875-7686
30
S ee us at Q UALITY EXPO T IM E Booth 1950

to outlast the machines they drive. In

most gear drives, the pitting rate is slow
enough that it can be tolerated with gear
replacement every few years. Sometimes
the increased vibration and noise caused
by pitting require a more permanent cure.
Fig. 5 shows a form of pitting known
as ledge wear, where the portion of the
tooth below the pitch line (dedendum) is
much more pitted than the portion near
the tip (addendum). The tooth is no
longera true involute form. This is cause
by a combination of p<x>r lubrication
conditions and mild overload. The mat
ing pinion wore in a similar pattern.
Such a gear can usually be saved by
recutting it and making a new hardened
and ground pinion (Fig. 6) that will
, TRU-VOLUTE
L the first name in gear generating tools

All TRU-VOLUTE gear generating tools are
precision ground to the highest accuracy.
If proven reliability and consistent
accuracy are important to you. then request
TRU-VOLUTE tools for your next j o b . ^ Proven Durability
Extensive Stock All Bore Sizes /
12 DP and finer
^
Available in HSS M42
/
and Solid Carbide
\
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Introducing Express Delivery I
and TRU-VOLUTE Class AA A ^
\
ultimate accuracy tolerances. \
promote a good lubrication film and hold

its accurate profile form under high
J^ U S S IU ,
loads. The accurate pinion acts as a tool

to maintain the gear tooth profile.
jJ o iB R O O K
The real issue, of course, is to prevent

pitting failures from occurring at all. Here
are some preventative steps:
1. Thicker (more viscous) oil spreads
the load over more tooth area and can
& ' f
f I N P E R S O N . IN C
Phone: 201-670-4220 Fax: 201-670-4266

2 North S treet, W aldw ick. N ew Jersey 0 7 4 6 3
C IR C L E A -1 2 on R E A D E R R E P L Y C A R D
1 9 3
13
increase the capacity of a drive without
Bourn & Koch CBN Form Grinder
much cost. It's worth a try with new

gears, but can't be expected to cure al
ready-pitted gears.
2. Extreme pressure (EP) additives in
the oil also can help. Synthetic oils with
out additives seem to hurt pitting resis
tance. Frequent oil changes, particularly
when the drive operates with oil tempera
tures above !60F. also help.
3. Harder gear materials definitely
make a difference. Changing from 180
to 3 2 1 Brinell hardness doubles pitting
capacity and changing to carburized
material doubles it again. The harder
C o m p o rt Polymer concrete base-column-tailstock

fe a tu re s Anti-friction way system
Gearless table drive

Unique environmental control
Industries most powerful conversational programming
Design for accuracy, performance and the operator
b o u ra n
oci
For all your gear manufacturing

requirements, whether it he new or
remanufactured, retrofitted or
rebuilt Barber-Colman gear
equipment. Roum <t Koch can offer
y o u the "Best Fit Solution. "
m acm ne ro o t co
PurcriMsm at
B trtm C o im s n U s a m r Tool O r a o n
2500 Kishwaukee St
Rockford, IL 61104
815/965-4013 Fax 815/965-0019
materials are more sensitive to mis

alignment (they can pit before they wear
in), so the replacement parts must be
made carefully and might require spe
cial geometry.
An economical way to repair a pitted
through-hardened gear set is to recut the
gear, exposing new surface material,
and to replace the pinion with a new
oversize carburized and ground pin
ion. The harder pinion will retain its
accurate profile, work-hardening and
SHOP FLOOR
The most accurate
gear is w a ste of
money if its m a teria l is
w ea k or b rittle . Only
the best m a teria ls
a:
w a rre n t the tim e and

r
Did you fill out the Reader

Survey Fax Form on
page 8 and return it to us?
effort necessary to
make an accurate gear.
protecting the gear from profile degra

dation. greatly increasing its life
This m aterial is adapted fro m Pitch
Lines, the bim o n th ly n e w slette r o f
YOUR OPINIONS MATTER TO US!
The G ear Works. Seattle. WA. R e

p rin te d w ith perm ission.
NEW 1993 BUYERS GUIDE

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GEAR P R O D U C TS INDEX
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For further information call (800) 451-8166
Controlling
Carburizing for
Top Quality Gears
Roy F. Kem
Kem Engineering Company,
Peoria, IL
A carburized alloy steel gear has the great
Many gear draw ings and/or carburize speci
est load-carrying capacity, but only if it is heat
fications require that the case depth be the
treated properly. For high quality carburizing,
distance inward, measured normal to the tooth
the case depth, case m icrostructure, and case
flanks where a certain hardness occurs. U niver
hardness must be controlled carefully.
sally. the depth is measured as that distance to
The depth o f penetration o f carbon into a
where a hardness o f 50 Rockwell C occurs. The
gear tooth is a function o f carbon potential of
most significant test location is at the lowest
the atm osphere, tem perature, time, and com po
point o f single tooth contact (LPSTC) m idway
sition o f the steel. Problem s with the produc
between the ends o f the teeth.
tion carburizing of parts start with the question:
This is much more com plicated than carbon
How and where is case depth to be measured?
penetration because this hardness is affected

not only by the carbon content o f the steel, but
also by its hardenability. the mass o f the tooth,
and, o f course, the vigor o f the quench.
The first step in case depth control is to
make sure that the gears mass, the hardenabi Iity
o f the steel in the gear, and the quench available
indicate that there is a possibility to meet the
case depth requirem ents. The most difficult
part o f this process is to estim ate the vigor of
the quench. This is done using the Jom iny endquench specim en showing in Fig. I.
The upper left-hand corner o f Fig. 1 shows
how an end-quench test is perform ed.
The specim en is heated to a hardening tem
perature and then quenched on one end with
water. The closer to the end. the more drastic
the quench is. and the harder the steel becomes,
as seen in the tw ice-scale draw ing at the bottom
Fig. 1 - The upper left-hand corner of the figure shows how an end-quench
test is perform ed with the Jomin.v end-quench specim en. O ne of the most
difficult parts of case depth control is estim ating the vigor of the quench.
o f the figure.
Note that at 1/16" from the quenched end,
the hardness is 45 Rockwell C. At 3/16" it is 41
Rockwell C, and at 6 / 16" it is 32 Rockwell C. If

a 3 DP solid pinion were made from this same
steel, the core hardness at the pitch line would
be 32 Rockw ell C. so the quench cooling rate at
the pitch line would be equal to 6/16" on the
Jom iny test specim en - com m only referred to
as J6. In the root fillet, the gear would have
hardened to only 28 Rockw ell C. which is
approxim ate J8. This has been done for both
web-type gears and solid pinions, as shown in
8 r
Fig. 2. and for round bars, as shown in Fig. 3.

For exam ple. Fig. 2 shows that the quench
cooling rate in the root fillet o f a 4 DP solid
pinion with an agitated oil quench corresponds
to 6 /I6 J or J6. The root fillet was chosen be
cause it is close to the LPSTC, and its quench-
S g
.5 7
1J iw
9
cooling rate is quite sim ilar.

For 9310 Steel. Fig. 4 show s all that is
needed at the req u ired case depth (to 50
Rock well C) is 0.30% carbon. So i f 0.0 6 0 case
depth is required, the carburized depth to 0.30%
carbon should be 0.060 plus approxim ately
0.010" or 0.070". This also is true of steels,
such as 3310, 4820. and EX-55.
L ean Alloys
W ith steels, such as 8620H and other lean
Diametral pitch
Fig. 2 - The quench cooling rate in the root fillet of a 4 DP solid pinion with
an agitated oil quench corresponds to 6/1AJ o r J6.
alloys, close control o f case depth becom es
Unless otherw ise specified, the case depth
much m ore difficult. This is because the hard
is determ ined by carefully cutting a 0.25"-thick
ening qualities o f these steels vary widely with
transverse slice from the sam ple's center. The
the m anufacturer.
slice is further reduced in size so it can be
The 4 DP solid pinion in Fig. 4 shows that
polished to a suitable m icroscopic finish. The
from 0.45% to more than 0.60% carbon is
hardness probe then is run from the surface
required at the specified depth below the sur
through the carburized case, using a graduated
face. depending on steel source, to harden to 50
stage with the first reading at 0.001" and the
Rockwell C. This variation is so great that for
balance at 0.005" steps. Either a Knoop or
precise control o f case depth the heal treater
Vickers hardness tester is satisfactory.
should run suitable carburizing tests on sam ples

from each heat o f steel before running parts.
Beyond the hardenability o f the steel, an
im portant factor in the control o f case depth is
the use o f a sam ple whose surface quenchcooling rate is the sam e as that at the test
The vigor of the quench also influences the

case depth, and yet tests and surveys have
shown that this important factor has received
little attention in gear hardening.
T e m p eratu re Dependency
Case depth depends on the temperature at
Roy F. Kern
This is im portant because it often is eco
The furnace therm ocouple perform ance
is president o f Kem En
gineering Co.. a design
and materials engineer
ing firm. He is an active
member o f the American
Society for Metals and
the author o f numerous
hooks and papers, in
cluding Hetec tint Steels
nomically impractical to cut a gear to check case
must be traceable to at least a secondary
fur Ucui Ireaim aii and
depth. Fig. 5 shows a suggested sample design
m aster standard calibrated by the N ational
and table o f sizes for different size gears.
Bureau o f S tandards.
location on the gear, for exam ple, at the LPSTC
which the operation is carried out. There are
or in the root fillet. Because there are quench
three factors to keep in mind regarding the effect
cooling rates in the root fillets for different
o f temperature on case depth:
types and pitches o f gears and for different size

rounds, heat treaters can plot the equivalents.
The furnace thermocouple must indicate

the temperature of the work.
Steel Selection with M.

Suessfor John Wiley and
Sons. New York.
1 3
17
The tem perature control device m ust be

operating properly, which is assured by a sched
uled and thorough m aintenance program .
It is not uncommon for the furnace therm o
couple to be. for exam ple, at I700F/927C
while the work, depending on mass, is 200F/
93C or more lower. The experienced heat
treater looks into the furnace as parts are being
heated to ensure that they are com ing to heat as
uniformly as possible.
C a s e M ic r o s tr u c tu r e
In a carburized gear, m icrostructure is ex

trem ely im portant. The desired com bination
for the case is m artensite, austenite, and finely
dispersed carbides. This structure must be free
o f microcracks.
The usual d e fic ie n c ie s are e x c e ssiv e
am ounts o f retained au stenite, carbide n et
w ork. or quenching p earlite, w hich often is
called upper bainite. W hen it is im practical to
cut a gear, specim ens as show n in Fig. 5 can
be used.
Fig. 3 - In the root fillet of round bars, the gear hardened to only 28
Rockwell C. which is approxim ately JK. Surface outside diam eter cooling
rate is expressed as J distance of round bars quenched in agitated oil.
W hat constitutes excessive am ounts o f re

tained austenite is a m uch debated m atter.
How ever, if a case hardness o f at least a 58
Rockwell C is obtained, the am ount o f auste-
Percent of C arbon K Fquired for 9310. 8620
nite present usually is not excessive. Still, a
9310 reheat hardened

mill: A D E C B
case hardness o f 60 Rockwell C is preferred.

The causes o f excessive austenite are one or a
com bination o f the following:
The steel being used contains too much
nickel and/or m anganese for the heat treating
practice em ployed.
8620H
Carbon content of the case is excessive,

for exam ple. 1.10% in 4820 steel, when 0.8%
is adequate.
Quench is extrem ely intense.
A reasonably reliable test for excess auste
nite is to find a gear quite file-hard, but Rockwell
C soft, for exam ple, in the low 50s. Parts having
excessive retained austenite can be salvaged in
more than one way.
If direct-quenched, the parts should be tem
pered at 500F/260C , reheated above the Ac
o f the core, and requenched. For steels such as
4817 and 4820. a two- to three-m inute delay or
20
.30
.40
.50
.60
.70
.80
.90
.100
percent carbon
Fig. 4 - W ith 9310 steel, all that is needed at the required case depth - to 50
Rockwell C - is 0.30% carbon. Depending on m anufacturer. 8620 steel
requires much m ore carbon.
greater resulting in cooling to I300F/704C

to I350F/732C betw een the hardening fur
nace and the quench also will reduce the re
tained austenite.
A nother way to salvage a part with exces-
sive retained austenite is to tem per the parts at

500F/260C and then charge in a carburizing
furnace at 1700F/927C to decarburize the
part surface down to the proper level. A fter
slow cooling, reheat to a tem perature 25 to
50above the Ac o f the core and quench.
Because it may substantially reduce the
bending fatigue q u alities o f a g ear tooth, lowtem perature treating at least dow n to -100F
and retem pering at 325F/163C to 350F/
177C is not a recom m ended m ethod o f reduc
ing retained austenite.
A nother im portant elem ent in carburized
case m icrostructures is the carbide m orphol
ogy. N etw ork carb id e is not perm itted due to
its w eakening and em b rittlin g effects on gear
teeth. C arb id e netw o rk is alw ay s the resu lt
o f e x c e ssiv e case c arb o n c o n te n t an d /o r in
adeq u ate h ard en in g in tem p eratu re. T he c o n
d itio n can only be d e te c te d in p ro d u c tio n by
m icro sco p ic e x a m in a tio n o f the c a rb u riz ed
surface o f a part or a slice from the sam ple.
T he p rev en tio n o f q u e n ch in g p e a rlite ,
w idely called upp er bain ite or sim ple bainite,
is an ad d itio n al elem en t in c o n tro llin g the
carburized case m icrostructure. T his c o n stitu
ent is soft, usually 30 to 40 R ockw ell C. It
also is w eak and d eleterio u s to p ittin g life, as
Fig. 5 - When it is economically im practical to cut a gear to check case

depth, a heat tre a te r can use a sample design and table of sizes for different
size gears.
show n in Fig. 6.
Q u e n c h in g P e a rlite
The heat treating operation can be at fault
for quenching pearlite form ation due to the
follow ing:
Inadequate case carbon content.
Excessive transfer tim e from the harden
ing furnace into the quench.
Inadequate quench intensity.
To get a steel to harden free o f quenching
pearlite, it must be cooled fast enough to avoid
the nose on the IT curves, down to at least the
M line: how ever. M is desired.
T he m ain reaso n fo r the p re se n c e o f
q u e n c h in g p e a rlite in g e a rs is s lu g g is h
quen ch in g . L eading edge heat treatin g firm s
avoid this undesirab le co n stitu e n t w ith v ig
orous q u en ch in g and also reduce steel cost
w ith low er co st alloy.
The ex trem e im p o rtan ce o f p reventing
quenching pearlite w arrants discussion o f some
steps to be taken in the choice process. Each
alloy steel, depending on the case carbon and
Fig. 6 Hainite, also call quenching pearlite, is soft, weak, and deleterious
to pitting life.
carburizing practice, h asaq uench-cooling rate
m icrocracks. M icrocracks adversely affect
in J distance below which quenching pearlite
bending fatigue life, although it varies with the
w ill form. Fig. 7 gives the typical cooling
severity and location o f the cracks.
rates, m ost o f which would be greater for a

case carbon content less than 1.00% carbon.
In the case o f bending fatigue life o f a 8620

steel that was reduced by a factor o f 1,000, the
For a 4 DP solid pinion, for exam ple, the
problem was solved by going to a 4020 analysis
quench-cooling rate in the root fillet is 6/16"J
steel 1018 plus 0.20/0.30% molybdenum . It
(0.375). If 1.00% case carbon is to be used by
is best to select material and heat treat process
carburizing at 1700/927C. cooling to I500F/
ing so there are no microcracks, which is an
816C and direct-quenching, only a few steels
achievable objective. If a few micro-cracks are
w ill harden w ith freedom from quenching
found on a single test, the chances are very good
pearlite. They are 3310, 4320. 4620. 4817,
that higher side heats will be more severely
EX-24, EX-29, E X -3 1,8822. and 9 4 B 17. Steels
cracked with significantly shortened lives.
3310, 9310, and 4817 will contain excessive
A slice from a sample or from a section o f a
am ount o f retained austenite with 1.00% case
scrap gear can be used for the microcrack speci
carbon. If the part is to be carburized to 1.00%
men. The etch must be very light, for exam ple,
case carbon, slow cooled, and then reheated
2% Nital for two seconds. With a more or less
for hardening, these steels will work: 3310,
normal etch, the m icrocracks will be invisible.
9310, 4320, and EX-31.
Although the hardness test is a crude ap
O f the two general types o f quenching, the
proxim ation o f the m etallurgical quality o f
first is a surface layer o f quenching pearlite
high quality carburized gears, it should be
frequently associated with intergranular oxida
perform ed at least once at the specified test
tion and/or partial decarburization. It usually is
location on each part. Preferably a m inim um
only 0.0015" to 0.002" maximum thickness,
o f three tests should be m ade and the average
and o f no significant engineering effect.
reported. There is som e evidence that the con
The second type is found as dark patches

deep into the surface. If 10 or greater stress-
tact stress capability o f a carburized gear is a

function o f its hardness.
cycle life is required, no quenching pearlite
The test location is very im portant, espe
should be present. If 10 cycles are adequate, 3%
cially on gears 6 DP and coarser. The best
maximum o f quenching pearlite is acceptable.
locations from a design standpoint are at the
Positive control o f quenching pearlite can
LPSTC for contact stress capability and the
only be done by m icroscopic exam ination o f a
root fillet for strength.
sam ple cut from a gear or a slice o f the speci
Coarse pitch gears are troublesom e. The
men. Exam ination should be at 400X to 500X
case carbon content is highest at the tips o f the
with a two-to four-second etch with 2% Nital.
teeth and decreases along the tooth flank to the
M ic ro c ra c k in g
root fillet. Also, if the quench is close to being
M icrocracking also must be considered in
deficient, the tips o f the teeth might be hard, but
suitable carburizing control. Such cracks are
not so with the case at the LPSTC and root fillet,
m ore prevalent in steels in which the major
because o f the lower carbon and less effective
alloying elem ents are carbide form ers, for ex
quench mainly due to vapor-pocket formation.
am ple, 4120 and 8620.

Case carbon content and quench vigor also
W hen gears cannot be cut up, there are

hardness testers that can nondestructi vely make
play an im portant role in m icrocracking. For
pitch line and root fillet tests. A nother means o f
exam ple, gears 8 DP and finer made from 8617
closely estim ating the case hardness at the
or 8620 will m icrocrack, even when reheat-
LPSTC or in the root fillet is to test the surface
hardened, when the case carbon is 0.90% or
hardness o f the m etallurgical requirem ent
greater, and the oil quench is well agitated.
sam ples as shown in Fig. 5. Usual case hardness
Heat treaters som etim es resort to w ater or a
requirem ents are 58, 59, or 60 Rockwell C
thin polym er quench to achieve the specified
minimum with a range o f plus 5 ,6 . or 7 points.
hardness on carburized steels such as 5120 or
A fast but very discriminating hardness tester
8 6 2 0 , but th is u su a lly re s u lts in sev ere
is a high-quality file. There is a certain amount
M icrostructure Capabilities of Carburizing Steels
Composition b
I0B I6(1.00 Mn. 0.17 Cf. 0.07 Mo)
1018
I0B22 (0.84Mn)
I5B24 (1.40 Mn)
1117(1.27 0.06 Cr)
1118
1213
1524
3310
4118
4120 (0.8 Mn. 1.00 Cr. 0.05 Ni. 0.25 Mo)
41B 16
4320
4620 (with 0.40 Mo)
4620
4817
5120
8620
8720
8822 (low side)
8822 (medium composition)
X9115
9120
94BI7
EX-15 (1.00 Mn. 0.50 Cr. 0.16 Mo)
EX-24 (0.87 Mn, 0.55 Cr, 0.25 Mo)
EX-29 (0.87 Mn, 0.55 Cr. 0.35 Mo. 0.55 Ni)
EX-31 (0.80 Mn. 0.55 Cr. 0.35 Mo. 0.85 Ni)
20 Mn Cr4
16 Mn Cr5
J distance to first bainite*

D irect-quenchc
Reheat-quench d
estimated
estimated
minimum
typical
typical
minimum
(inches)
(inches)
(inches)
(inches)
0.138
0.075
0.122
0.122
0.122
2.000+
0.960
2.000+
0.232
1.270
0.385
0.760
2.000
0.375
0.375
0.075
0.050
0.075
0.100
0.062
0.062
0.062
0.100
2.000
0.062
0.075
0.100
0.875
1 250
0.750
2.000
0.050
0.200
0.300
0.750
1.000
0.075
0.075
0.500
0.200
0.300
0.750
2.000
0.285
0.250
0.122
0.055
0.105
0.116
0.116
0.118
..
2.000+
0.085
0.114
0.186
0.250
0.272
2.000+
0.080
0.108
0.132
0.189
0.300
0.104
0.084
0.173
0.116
0.188
0.188
0.062
0.030
0.062
0.100
0.062
0.075
0.062
0.100
2.000
0.075
0.100
0.125
0.875
0.200
0.250
2.000
0.062
0.100
0.100
0.185
0.250
0.075
0.075
0.150
0.100
0.200
0.300
2.000
0.100
0.150
a In inches at 1.00%.
b Composition given for nonstandard and experimental steels only,
c Direct-quench consists o f carburizing at I70F, cooling to 1550. and quenching,
d Reheat hardening consists of carburizing at I700F. slow cooling to room temperature, rehealing tp
1550F. and quenching. No tempers.
Stiurce: Climax Molybdenum Co.
Fig. 7 - Kach alloy steel, depending on case carbon and carburizing practice, has a quench cooling rate
in J distance below which quenching pearlite form s. Listed above a re typical cooling rates, most of
which would be g rea ter for a case carbon content less than 1%.
o f art required to run the test, but generally it

consists o f ju st laying a file on the surface to be
tested, applying a m oderate am ount o f dow n
ward pressure, and then m oving the file slightly
forw ard. If the file "bites." the hardness is
Unpublished. 1985.
3. Kern. R. F. and M. Suess. Steel Selection - A Guide
fo r Improving Performance <fi Profit. John Wiley and
Sons. New York, 1979. p. 186.
4. Kern. R. F. "New Dimension in Selecting Carburiz
ing Steels. Metal Progress. October, 1972. p. 127.
questionable. If another application o f the file to

the same area removes metal, the surface is filesoft. This test will detect partial decarburization
and structures with quenching pearlite
References:
1. Kem. R. F. Control of Carburized Case." Heat
Treating. March. 1985, pp. 22-3.
2. Kern. R. F. "Effect of Manganese & Nickel on the
Hardening Capability of 8620 and 8822 Steels.
Acknow ledgements: Based on a paper presented at

the AGMA Technical Education Seminar, May 8,
1990. The original paper is copyrighted by AGMA and
used with permission. AGMA states that the opinions,
statements, and conclusions in the paper are those o f
the author and in no wav represent the position or
opinion o f the association. This version o f the article
is reprinted from the March, 1991, issue o f Heat
Treating magazine. Used with permission.
19 9 3
21
Dual Frequency
Induction Gear
Hardening
John M. Storm & Michael R. Chaplin
Contour Hardening, Inc.,
Indianapolis, IN
In tro d u c tio n
Selective carburizing is an industrial stan
In the typical gear production facility, m a
dard most widely used to selectively harden
chining o f gear teeth is followed by heat treat
gears. The process involves covering the sur
ment to harden them. The hardening process
faces to be protected against carburizing with a
often distorts the gear teeth, resulting in reduced
material that prevents the passage o f active car
and generally variable quality.
Heat treating
bon during the furnace operation. The most widely
gears can involve many different types of opera
used method to stop carbon activity is copper
tions, which all have the common purpose of
plating. A gear is copper plated on all surfaces
producing a microstructure with certain optimum
except the teeth, then carburized. The part is then
properties. Dual frequency induction hardening
copper stripped, finish machined, re-coppcr plated
grew from the need to reduce cost while improv
all over, furnace hardened, and quenched.
ing the accuracy (minimizing the distortion) of
Dual frequency heating is the fastest known
two selective hardening processes: single tooth
way o f heating a gear. Heating times range from
induction and selective carburizing.
. 14 to 2.0 seconds. Because it is so fast, surfaces
Single tooth induction hardening is performed
remain clean and free from carbon-depleting
with a shaped intensifier that oscillates back and
and scale, and the core material retains its origi
forth in the gear tooth space. It is usually done
nal properties.
with the gear submerged in quench. The process
The focus on manufacturing today is to make
is relatively slow because only one gear tooth
consistently high quality products at lower costs.
space is processed at a time.
This article describes the dual frequency process

along with comparisons of other heat treating
processes and actual heat cycle data.
Dual Frequency Process
The principle of dual frequency heating em
ploys both high and low frequency heat sources.
The gear is first heated with a relatively low
frequency source, providing the energy required
to pre-heat the mass of the gear teeth. This step is
followed immediately by heating with a high
frequency source. When applied, the high fre
quency source will rapidly final heat the entire
Fig. 1 C ontour gear hardening pattern.
22
tooth contour surface to a hardening temperature.
The gear is then quenched to a desired hardness.

Figs. 1 and 2 show a typical "dual frequency"
contour hardened pattern.
The total time cycle is dependent upon the
surface area to be hardened. See Table I.
M aterial R eq u irem en ts
There have been vast amounts written about
material requirements in terms of wear, machinability. mechanical properties, and the ease with
which complicated shapes may be produced by
casting methods.
OUTSIDE
DIAMETER
(Scction B-B)
In general, a wide variety of
materials can be used for the production of gears.

For technical and economic reasons, steels have
"C'o .t v c n ] -
attained a major importance.

The transform ation w hich the structure o f
ROOT
DIAMETER
(Scction A-A)
steel undergoes during heating and subsequent

cooling, particularly the form ation o f m arten-
ki-N vXkSX'SJXWWNi.TT-v\\
site on quenching, is essential for the hardening
TOOTH MID HEIGHT

(Scction C-C)
and tem pering o f steel. The carbon content of

steel establishes the m aximum hardness that
the steel can reach. Com m only used induction
Fij;. 2 - Typical tip and root pattern.
steel requires a carbon content o f .40/.50/.60% .

depending on the desired surface hardness.
Table I - Dual Frequency Process
Parts w hich have to be hardened by quenching

Gear Data
after local heating must he made of a steel which

contains the carbon necessary to achieve a desired
hardness, as shown in Table II.
H eat Cycle Test
Ideal contour induction processes rapidly heat
with only the required energy to transform a
Numberof teeth.................................................... 58
Outside diam eter.......................................... 7.500
Root diameter.................................................. 6.930
Face w id th..........................................................490
Material.................................................... SAE5I50
Approximate surface area = 27 square inches
desired volume o f material; i.e.. the contour sur
John M. Storm
face o f a gear, and allow for extreme, rapid

Dual Frequency Cvcle Process
quenching to take place. This "m ass quenching"

effectively produces a maximum surface hard
ness from the material and the best condition of
microstructure available (fine grain martensite).
The real problems associated with the heat
treating of gears arc the result of the numerous
* Pre-heat
* Dwell
* Final heat
* Quench
* Temper
10
3
.455
15
3
seconds
seconds
seconds
seconds
seconds
(spindle rpm)
300
400
5
300
processes added to the manufacturing sequence to

correct for distortion caused by heat. Most gear
Dual Frequency System
producers work from green specs and hard specs,

before and after heating, in the hopes of accu
rately predicting the amount of change that will
take place because of heating.
This typically
* Prc-hcat low frequency generator (3 -10k)

* Final heat high frequency generator ( I00-230kc)
* Work station with quench system
* Computer control station
involves machining over/between pins. lead, and

involute dimensions to values different from
Table II
final print requirem ents. In this mode of opera

tion. the manufacturer treats the sym ptom s and
RC
CARBON
not the true problem . In treating the sym ptom s,

a sizeable increase in gear production cost is
generated. The m ajor elem ents that produce the
increased costs include materials, time, energy.
50
55
60
.40%
.45%
.51%
is Vice President o f Re
search and Development
at Contour Hardening,
Inc. He has worked for
nearly twenty years in
heal treating process re
search and. along with
Michael Chaplin, has
been granted a patent for
the Micropulse contour
hardening system. He is
a member o f SME. ASM.
and AGMA.
Michael R. Chaplin
is Vice President o f En
gineering at Contour
Hardening. Inc. He has
28 years' experience in
gear box design and gear
development in aero
space and transmission
applications. He is cur
rently Chairman o f the
AGMA Vehicle Gearing
Committee and U.S. del
egate to the ISO Com
mittee TC/32.
1 ( 1 1
23
Table III
Comparison of Dual Frequency Induction Gear Hardening and Selective Carburizing
DIE QUENCH OPERATION
FREE OUENCH OPERATION
1. Rough Machine
2. Degrease
3. Mask
4. Copper Plate
S. Unmask
6. Inspect Plate
7. Load Carburize Furnace
8. Slow Cool
9. Clean
10. Copper Strip
11. Finish Machine Gear Teeth
12. Load Hardening Furnace
13. Die Quench
14. Degrease
15. Draw (temper)
16. Shot Blast (clean)
17. Inspect
18. Required Finishing Operations
1. Rough Machine
2. Semi-finish Gear Teeth
3. Copper Plate
4. Unmask
5. Inspect Plate
6. Load Carburize Furnace
7. Quench
8. Draw (temper)
9. Degrease
10. Shot Blast
11. Copper Strip
12. Shot Blast
1 3 .Inspect
14. Required Finishing Operations
DUAL FREOUENCY OPERATION

1. Rough Machine
2. Core Treat
3. Degrease
4. Draw
5. Finish Machine (final size)
6. Load Induction Machine
7. Unload
8. Inspect
for the automotive industry:

Residual stress level
Microhardness gradient
Pattern depth of penetration
Before and after dimensional characteristics
The residual stress evaluation was made on a
comparative basis to determine relative root re
sidual stress levels in gears hardened via different
methods. Residual compressive stress is favor
able because it tends to subtract from an intensity
o f the tensile stresses during operation of the gear.
Residual stress levels were measured by the
"Fastness" method to determine root compressive
stress. The dual frequency method was found to
have 120,000 psi compressive at 1.003 inches.
Fig. 3 - R esidual com pressive stresses.
and added processing.

The dual frequency gear hardening process
Fig. 3 shows the comparison between the carburize and harden method, single tooth induction,
and dual frequency hardening.
treats the problem by reducing or elim inating
Fig. 4 shows the microhardness gradient at
the distortion o f gear teeth through heating to
three positions across the teeth. Figs 5a and b are
levels acceptable in most gear final print to le r
gear inspection charts taken from a CNC univer
ances. T able III show s the operations required
sal gear checker. They show the "before" and
to m anufacture gears utilizing three different
"after" lead, involute, and runout checks.
hardening methods.
To selectively harden gear teeth utilizing (he
C onclusion
Even in an age of high technology, heat treat
selective carburizing process, they must be
ing of gears leaves much to be desired. Invariably,
handled (load/unload) a minimum o f 16 times.
the imperfections of the process create dimen
In addition to handling the part, numerous in
sional distortions, which, in addition to other
spection and support personnel are needed to
difficulties, can yield a production fallout" of
maintain plating solution and equipment.

The following physical characteristics were
evaluated on six diametral pitch production gears
10% to 20% or can lead to rework operations in an

effort to salvage the gears.
Until now, industry just had to live with the
Microhardness Gradient
r v PROFILE
\ (Center)
i
> -
ROOT
(Center)
ROOT
(Face)
Depth of penetration - parts were

sectioned, and the fol lowing depths
were measured:
PROFILE (Center)
DEPTH (ins.) RC
ROOT (Face)
DEPTH (ins.) RC
ROOT (Center)
DEPTH (ins.) RC
.(XX)
.010
.020
.040
.060
.080
.100
.120
.000
.010
.020
.040
.060
.080
.100
.210
.000
.010
.020
.040
.060
.080
.100
.120
60.4
58.2
56.7
58.2
56.7
33.7
33.7
33.7
60.5
60.0
60.4
57.4
56.2
34.2
34.2
34.2
615
61.2
60.4
55.9
52.1
33.7
33.7
34.2
SERIAL
NUMBER
PRE-HEAT
TIME (sec.)
FINAL HEAT
TIME (sec.)
AVG. CASE DEPTH AVG. CASE DEPTH

ROOT (ins.)
TIP (ins.)
1
2
3
4
5
6
7
9
12
13
15
20
26
27
29
45
40
32
35
35
40
40
42
38
40
44
38
38
36
32
.75
.75
.75
.45
.70
.85
.70
.70
.65
.55
.60
.80
.75
.75
.75
.046
.046
.042
.028
.035
.048
.045
.045
.032
.030
.032
.044
.042
.040
.040
.120
.108
.080
.090
.092
.092
.108
.113
.094
.106
.117
.103
.105
.090
.080
Fig. 4 - M ic ro h a rd n ess g rad ie n t.
Fig. 5a - G e a r inspection c h a rt - befo re.
problem.
Now a new heat treating system has
overcome those traditional limitations, not with

untried technology, but with an innovation on estab
lished technology. The system provides advanced
induction heating with the total, repeatable accuracy
Fig. 5b - G e a r insp ectio n c h a rt - a fte r.

A cknow ledgem ent: P rinted with perm ission o f
the copyright holder, the Am erican G ear M anu
fa ctu rers A ssociation. Alexandria. VA. The o p in
ions. statem ents, and conclusion p resented are
those o f the A uthors and in no way represent the
position or opinion o f the Association.
o f programmable microprocessor control.

1193
Frozen Gears
Pete Paulin
300 Below, Inc.
Decatur, IL
Durability is the most important criterion
and resharpening will not destroy the treatment.
used to define the quality o f a gear. The freezing
The process has a number of obvious benefits,
of metals has been acknowledged for almost
including increases in tensile strength, toughness,
thirty years as an effective method for increasing
and stability through the release of internal stresses.
durability, or wear life." and decreasing residual
The exceptional increase in wear resistivity, gen
stress in tool steels. The recent field o f deep
erally exceeding 200%. is the greatest benefit.
cryogenics (below -300F) has brought us high-
Steel surfaces receiving wear, such as gears,
temperature superconductors, the superconduct
shaper cutters, drill bits, end mills, taps. dies,
ing super collider, cryo-biology, and magneto-
surgical scissors, bearings, racing engines, she
hydrodynamic drive systems. It has also brought
ers. and granulator knives, all benefit from this
many additional durability benefits to metals.
inexpensive treatment. New applications are be
The deep cryogenic tempering process for

gears is an inexpensive, one-time, permanent
treatment, affecting the entire part, not just the
surface. Gears may be new or used, sharp or dull.
ing discovered regularly.

C om pleting the H eat T re atin g Process M artensitic T ransform ation
A research metallurgist at the National Bu
reau of Standards states, When carbon precipi
tates form, the internal stress in the martensite is
reduced, which minimizes the susceptibility to
microcracking. The wide distribution o f very
hard, fine carbides from deep cryogenic treatment
also increases wear resistance." The study con
cludes: ... fine carbon carbides and resultant tight
lattice structures are precipitated from cryogenic
treatment. These particles are responsible for the
Fig. 1
exceptional wear characteristics imparted by the

Sta n d ard heal treating/m l te m p e rin g
process, due to a denser molecular structure and

resulting larger surface area o f contact, reducing
friction, heat, and wear."
Metallurgists have been skeptical o f the cryo
genic process for some time, because it imparts no
apparent visible changes to the metal. The think
ing is that since proper heat treating changes 85%
of the retained austenite to martensite, and the
deep cryogenic process only transforms an addi
tional 8 - 15%, deep cryogenic treatment is an
inefficient process.
C: Heal treat with shallow cryogenic cycle added.

G: Heat treat with shallow cryogenic cycle and temper.
H: Heat treat with temper, then shallow cryogenic cycle added
M: Heat treat with temper, then shallow cryogenic cycle, then temper.
N: Heat treat w ith temper, then shallow cryogenic cycle, then temper, cryogenic cycle and temper
Fig. 2
These are correct premises, but an inaccurate

conclusion. Deep cryogenically cooled metals
also develop a more uniform, refined microstructurc with greater density. Microfine carbide fill
ers are formed, which take up the remaining
space in the micro-voids, resulting in a much
Picos of The Polytechnic Institute of Jassy. Ro
denser, coherent structure of the tool steel. The
mania. utilized the latest scientific equipment
end result is increased wear resistance.
available, a JEOL IXA-5A Electron Probe, a
These particles are the same ones identified
D RO N -1 X-ray Diffractometer, a Quantimet 720
and counted in the accompanying study using a
Quantitative Microscope, and a Chevenard Dif
scanning electron microscope with field particle
ferential Dilatometer to supply the following re
quantification. (An automatic particle counter.) It
sults from the extensive study.
is now believed that these particles are largely
The study involved 7 samples (A-N in Fig. 2).
responsible for the great gains in wear resistivity.
each subjected to a different tempering cycle as
Unlike the case of coatings, the change created is
noted. Each sample was the equivalent of M2
uniform throughout and will last the life of the
steel; each sample had the carbide particles physi
tool, regardless o f any subsequent finishing op
cally counted, both before and after the deep
erations or regrinds. It is a permanent, irreversible
cryogenic treatment. The team then measured the
molecular change.
samples with the equipment above, and with
The two I000X micrographs shown in Fig. I
standard metallurgical evaluative testing. The
represent samples from the same S-7 bar stock.
results confirm with tangible evidence the carbide
The first is untreated S-7. The second was deep
precipitation in cryogenic processing.
cryogenically treated. The martensitic transfor

mation is readily apparent.
All the metal samples were taken from iden

tical batch stock. The sample structure was com
Field T esting Proves
prised of 839K:. .38%Mn. ,3% S.4.1% C r.5.1%Mo,
Deep C ryogenic Potential
1.92% V. and 6.3% W. Samples were all simulta
The cryogenic cycle is an extension o f stan
neously standard heat treated at 1230C. then
dard heat treatm ent, and creates many out
oil-quenched. Four of the pieces were then sub
standing increases in durability. For exam ple, a
jected to the cryogenic cycle at -70C with
major aircraft m anufacturer testing deep cryo
varying tempers added after cold soaking.
genics found that with only six different tools

treated, the savings in tool purchases could
exceed $5 million.
The deep cryogenic treatment o f an 8% co
balt end mill has dem onstrated dram atic im
Findings
The results of the testing conclude with the
following findings and analysis comparing stan
dard heat treating to heat treating with the addi
tion o f a shallow cryogenic soak:
provem ents in tw o important ways. The number
Austenite decreased from 42.6% to 0.9%.
o f milling cuts was increased from three before
Martensite increased from 66% to 81.7%.
deep cryogenic processing to 78 after process
Carbides increased from 6.9% to 17.4%.
ing. 26 times the wear life. Resharpening the end
Mean number of carbides counted @ I mm sq.
mills after deep cryogenic treatment required

only 1/3 the amount o f stock removal to restore
the tool geometry.
Rockwell, a major aircraft manufacturer run
ning C-2 carbide inserts used to mill epoxy graph
ite. doubled its output after deep cryogenic treat
ment. In a second test used to mill 4340 stainless
steel, it achieved a 4<X)% improvement.
Other applications include leading national
stock car auto racers, who previously raced
only 4-8 races betw een teardow ns, went to 40+
races after treating the block, crank, cam. pis
tons. and heads.
increased from 31.358.17 to 83,529.73.

Number o f carbides less than 1 pm in size
increased from 23.410.24 to 69,646.09.
Rockwell increased from 60.10 to 66.10.
T ensile strength increased from 86.0 to
244.46.
Bending strength increased from 86.0 to
244.46.
KCU (resiliency) increased from 0.668 to
1.18.
HRC 675C after 20 minutes keeping: 56.88
to 62.25.
Durability o f the cutting time increased from
L ab Results C onfirm the Field Testing
20 minutes to 45 minutes with a shallow cryo
The latest research data on cryogenic temper
genic cycle.
ing confirms the long standing theory that cryo
Fig. 2 illustrates the seven separate heat/cool
genic treatment significantly enhances cutting
cycles used to temper the lathe cutting tools. The
tool life. Dr. Joan Alexandru and Dr. Constantin
lathe cutting tools were then used to cut a .5%
Pete Paulin
is the president o f 300*
Below. Inc. He has a de
gree in aeronautical sci
ence from Embry-Riddle
Aeronautical Univer
sity, Bunnell. FL He hat
published several other
articles on cryogenic
research.
structural carbon steel. Durability was estab

lished by measuring the radial component of
wear. Intensive Speed: @33.6m/min.; Depth:
5mm; Feed: 0.62mm per rev. Relief angle: 8;
Hake angle: 5: Plan angle: 45.
Deep C ryogenic Cycle Doubles the
Results of the Shallow C ryogenic Cycle
Separate laboratory testing has been performed
by Dr. Randall F. Barron at Louisiana Tech
University. Ruston, LA. The results by Dr. Baron
confirm the Jassy study even further. In one
series o f tests Dr. Barron compared five com
mon steel alloys. First he tested them as pro
cured. Then he chilled them to -120F, tested
Sample ID
them again, and then treated them at -3I7F. In

all cases the cold treatm ent im proved wear
Fig. 3
resistance. The colder the treatm ent, the better.

Wcjir Improvement uf Shallow Cryogenic <- 120F) Cycle vi Deep Cryogenic (-320K) Cycle
700* Gain
The - 120F (dry ice) treatm ent im proved ratios

ranging from 1.2 to 2 tim es, depending on the
alloy. This is consistent with the Jassy findings.
H ow ever, the deep cryogenic treatm ent at
3 17F improved wear resistance by even greater
ratios ranging from 20 to 6.6 times.
Process Developm ents
The deep cryogenic process has had an Achil
les heel. It has been inconsistent. In the past,
improvements to gears would vary from little
improvement to over a 1,000% increase in useful
life. The trick is in the processing. Temperature
52100
changes must be controlled exactly for consistent

Fig. 4
results. If a gear or tool is dropped in liquid

Table I
TEST RESULTS: Percent of Increase in
W ear Resistance After Cryogenic Tem pering
nitrogen, it could shatter.

The computer processor solves this problem.
The computer can duplicate the optimal cooling
Materials that showed significant Improvement

M SI#
D-2
S-7
52100
0-1
A-10
M-l
H-I3
M-2
T -l
CPM-10V
P-20
440
Description
High carbon/chromium die steel
Silicon tool steel
Standard steel
Oil hardening cold work die steel
Graphite tool steel
Molybdenum high-speed steel
Chromium/moly hot die steel
Tungstcn/moly high-speed steel
Tungsten high-speed tool steel
Alloy steel
Mold steel
Martensitic stainless
A I-110F
316%
241%
221%
230%
145%
164%
117%
141%
94%
123%
128%
curve exactly time after time after time.

At -310 F
817%
503%
420%
418%
264%
225%
209%
203%
176%
n r;
130%
121%
Ferritic stainless
Austenitic stainless
Nickel-chromium-moly alloy steel
Carbon steel
Graphitic cast iron
Tungsten high-speed steel
R V B u r n m tlu J v m u l t i
D EA R
L im iiiu iu i P o ty tf t h /iu In stitu te
T E C H N O L O G Y
116%
105%
112%
97%
96%
72%
cake in a wood-fired stove. The newest cryo

genic tempering systems achieve consistent re
sults. Furthermore, the price enables the gear
manufacturer to improve his profit margin, im
prove his product, and increase market share
with a superior product.
T he Cry ogenic T em pering Process
The new m achines operate with controlled
dry thermal treatm ent. C ontrolled" simply
Materials that did not show significant improvement.

430
303
8620
C-1020
AQS
T-2
Older cryogenic tanks did not have adequate

control. Using them was like trying to bake a
119%
110%
K)4f;
98%
97%
92%
means that the process is perform ed according

to a precise prescribed time table. A 386 PC is
utilized as the process controller operating the
descent, soak, and ascent modes. The material
is cooled slowly to -3J7F, held for 20-60
hours, then raised to + 375F , and slow ly
retu rn ed to room tem p eratu re. It is a "d ry
should be more pronounced for 440 stainless
pro cess in that, unlike o th er deep cry o g en ic
steel than for the other stainless steels.
processes, it does not bathe the m aterials in
C -1020 carbon steel and QS Meehanite iron
liquid nitrogen, which is more likely to cause
also show no significant improvements in per
dam age from therm al shock.
formance after cryogenic treatment. Because
How It W orks
The Barron study looked at how the changes
brought about by cryogenic treatment affected
steel's ability to resist abrasive wear. It found
these materials contain no austenite. sub-zero

temperatures can cause no further metallurgical
changes in them.
Financial Potential
that the martensite and fine carbide formed by
Liquid nitrogen is the largest processing cost
deep cryogenic treatm ent work together to re
in cryogenically cooling gears. The newest sys
duce abrasive wear. The fine carbide particles
tems are designed to more efficiently transfer cold
support the m artensite matrix, making it less
from the liquid nitrogen to the metal parts being
likely that lumps will be dug out of the cutting
treated without losing the cold to the outside.
tool material during a cutting operation and
They have reduced processing costs by half,
cause abrasion. W hen a hard asperity or foreign
making it economical to process all types o f steel
particle is pressed onto the to o ls surface, the
items, not just gears and tooling. Gears now cost
carbides further resist wear by preventing the
pennies instead of dollars to treat with this method.
particle from plowing into the surface.
Potentially every gear which is heat treated is a
Some o f these benefits may be achieved
candidate for the additional service of cryogenic
through standard tempering, which also trans
tempering. Most customers are pleased to pay for the
forms austenite into martensite. But standard tem
additional improvement of any gear, especially at a
pering may not bring about a com plete transfor
nominal additional cost (less than SI per pound!).
mation in some tool steels. Forexam ple. 8.5% of
There are more than a handful of large tooling
an 0 -1 steel rem ains austenite after it is oil-
manufacturers quietly utilizing the process today
quenched to 68F. If M -l is quenched from
for manufacturing a premium line of cutting tools.
222F to 212F, then tempered at I049F, the
They manufacture a premium" tool which lasts
retained austenite is 11%.
2-5 times longer for pennies and charge dollars
Additional improvements in tool performance
more for it - a great boost in a competitive market
can be achieved if this retained austenite can be
place where profit margins have been squeezed.
transformed to martensite. As B arron's study has
Some heat treatcrs offer cold cryogenic ser
confirmed, adding a cryogenic step to the treat
vices" utilizing -120F (dry ice) systems, but deep
ment process does just that.
cryogenic treatment (below -300F) is where most of
In Table I. data drawn from another study of
the benefits occur. Ultra low temperature treatments
treated metals by Barron indicates which samples
below -300F show much more impressive results.
exhibited improved abrasive wear after cryo
Conclusion
genic treatment. In addition to results obtained
While not a magic wand which will extend the
from sam ples treated at liquid-nitrogen tem
life o f every product, over 100 items, such as
perature (-310F), the chart also lists results of
gears, ream ers, taps, dies, broaches, drills,
treatment at dry-ice temperature (-1 10F).
endmills, slicers, and cutting knives do respond to
How F.fTective Is It?

Knowing how deep cryogenic tempering works,
the process. It can create a premium more

profitable tool gear for a manufacturer and save a
we can predict which materials will benefit most
lot of tool expense dollars for end users. The
from treatment. Generally, if an alloy contaias
process is effective throughout the tool, unlike a
austenite. and this austenite responds in some de
coating, so tools can be resharpened and receive
gree to heat treatment, further improvements will
the benefits until completely worn out. The pro
be seen after deep cryogenic tempering. For in
cess also works with TiN coatings.
stance. ferritic and austenitic (430 and 303) stain
Among the properties w hich define the quali
less steels generally cannot be hardened by heat
ties o f a gear steel, durability is the highest
treatment. Martensitic (440) stainless steels, on the
importance. These results are decisive in estab
other hand, can be hardened by heat treatment:
lishing the benefits o f cryogenic treatment in
therefore, the effect of deep cryogenic treatment
increasing durability.
Improving Gear
Manufacturing Quality
W ith Surface Texture
Measurement
Mike Moyer
Rank Taylor Hobson, Inc.
Des Plaines, IL
The working surfaces of gear teeth are often the
On today's sophisticated metrological devices,
result of several machining operations. The surface
these categories are evaluated by their wave
texture imparted by the manufacturing process
lengths. The short wavelengths o f roughness are
affects many of the gears functional characteris
caused by fracturing, cutting, grinding, or honing.
tics. To ensure proper operation of the final assem
The medium wavelengths of waviness represent
bly, a gear's surf ace texture characteristics, such as
short term m achine errors, such as a single
waviness and roughness, can be evaluated with
aberrant revolution o f a spindle, while long
modem metrology instruments.
wavelengths o f form are the result o f tool path
W hat is Surface Texture?
errors, such as straightness.
Simply stated, the surface texture o f a gear
The process of measuring and analyzing sur
tooth is the surface that is the result of the manu
face finish is called "surface texture metrology."
facturing process. In machined gears, surface tex
When the technology of metrology is applied to
ture is the result of the tool passing over the tcxnh;
gear manufacturing, the engineer has a powerful
in molded or cast gears, it is the combined result of
tool to assist the analysis of a gears ability to retain
the material, mold, and molding process.
RTH Form Talysurf Series

Results Page
10.00 pm
lubrication, distribute force, run quietly, and with
In more technical terms, the manufactured
stand wear, all of which may be related to surface
surface can be defined by three general measure
texture. Lubrication, for instance, is retained in the
ment categories: roughness, waviness, and form.
valleys that have been created on the surface. On

the working surface, stress is increased by the
Form Tly*urf Series

No Filter/Ellipv;
presence of robust peaks and deep valleys. Noisy

Bearing Ratio/
Amp distb.
M odified Profile
operation may be the result o f waviness and chat

ter. and wear may be attributed to many causes,
1 0 .0 0 Mm J
0.000 Mm
such as the lack of a load-bearing area.
5.8 5 1 Mm
Major Axis Radius 9.1812 mm. Minor Aais Radm% 4.7186 mm

1.4381 Mm
PRa
Delq
6.3562 dcg
prh
1.7617 Mm
Lamq
99.3665 Mm
4.5271 Mm
PRp
S
12.3667 Mm
7 6989 Mm
PR /ISO
PRv
7.5123 Mm
12 2260 Mm
Sm
PR t
223.3542 Mm
0.1469
PRsk
Lo
5 8964 mm
2.7726
PRku
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With the proper surface metrology equipment,

common gear problems can be discovered before a
gear goes into the final assembly. Currently, there
Form
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are two basic categories of instruments used to

evaluate surface texture: a) the simple roughness
average instrument, and b) the more sophisticated
engineering quality instrument.
Fig. 1
30
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How is Surface T exture M easured?

Re-Analyte
T E C H N O L O G Y
Standard averaging instruments are low-cost

devices that are commonly found on the shop floor.
with less distortion. The benefit is simple: more

accurate measurement.
Because they lack the sophisticated technology
Today's instrument offers high-resolution dis
required to measure complex forms and present
play of results. Gone forever are strip chart record
multiple parameters, these instruments are capable
ers with their poor frequency response and balky
only of the limited evaluation of a straight surface.
operation. For highly accurate and readable dis
On the other hand, the engineering quality
plays, the most recently developed metrology equip
device is capable of detailed analysis o f surface
ment lakes advantage of VGA graphics and high-
texture parameters, waviness parameters, radial
resolution printers.
size, and straightness. These instruments are
Mathematic removal of the circular form al
generally found in the laboratory or inspection
lows improved accuracy. Form removal tech
area, but smaller and more durable versions of
niques ensure accurate results on curved surfaces.
this instrument are now available for use at the
The computer permits the quick and easy removal
point o f manufacture.
of mathematically defined and empirical forms.
Recent Technological Advances in
Once the form is removed, the texture is evalu
M etrology Instrum ents
ated as if it were on a straight surface, providing
The technological evolution from the averag
improved accuracy while allowing easier analysis.
ing instrument to the engineering quality device is
More advanced instruments also provide a
a giant leap in metrology. In fact, it can be said that
wide range o f analysis in the form of numeric
the difference between the two is akin to the differ
parameters. With today's metrology equipment,
ence between superstition and science. A quick
the engineer has a wide selection of parameters
glance at the disparity between these two machines
from which to choose. These arc the tools engi
will make this difference immediately apparent.

The engineering quality instrument features a
high resolution, wide range transducer to a) ease
setup, b) permit operation with a range o f surface
neers depend on to numerically define an accept

able surface. Commonly used parameters include:
Averaging parameters: Ra, Rq. Rpm. Rz
(DIN).
forms, and c) offer improved accuracy by eliminat
Waviness parameters: Wa. Wq. Wz (DIN).
ing skids. Transducers with dynamic ranges of .04"
Peak parameters: Rp. Rv. Rti. Rt. Ry, Wp,
make it easier for the user to stage the part being

inspected. Accurate readings can be obtained when
Wv. Wt. Wti. Wy.
Hybrid parameters: skew, kurtosis
the traverse is not perfectly parallel with the sur
Amplitude distribution and bearing ratio
face to be measured. For the highly sophisticated
(Abbott. Firestone) curve interpreters: Rk. Vo.Tp,
user, a transducer with .24" range and .0000004"
Pc. HSC. Htp.
resolution is available. This transducer is fre
How Surface T exture Metrology Fits Into
quently used to measure the size of circular shapes.
The Design and M anufacturing Process
And the latest advances in transducers have led
When initiating a new design, a product engi
to the elimination of skids. Although they eased
neer must choose the surface parameter which
setup by establishing a local datum, skids also
controls the features important to the function of
contributed to system error.
the finished product. This is the description that is
Two-axis coordinate measuring machine prin
put on the print for the finished product. Only then
ciples improve the metrology technique. The mod
can the appropriate metrology instrument and
em engineering instrument is a true two-axis coor
procedure be selected.
dinate measuring machine with extremely high
The manufacturing engineer's task differs
resolution and very good straightness on travel.
from that of the design engineer. The manufactur
The high number of data points collected describe
ing engineer is concerned not only with the fin
the surface with extremely high fidelity.
ished part, but also with the part in process. If a
Digital electronics eliminate analog filters and
gear is to be hobbed. ground, and honed, a prudent
improve stability. Because the metrology equip
engineer knows he will need tocontrol the surface
ment now works with numbers rather than ana
texture at each stage to minimize cost and assure
log voltages, a com puter is used to m athem ati
final quality. For example, if we can assure a
cally filler the results. This technique greatly
consistent surface texture range from the hob, we
improves accuracy and permits the use o f filters
can control the grinding operation to minimize

19 9 3
cutting depths, reducing heal and distortion. A
Form Talysurf Series

Rough/Gauss/6 0.8mm. 100 l/Hllipsc
Results Page
consistent grinding finish means we can predeter

mine the honing cycle time.
Case Studies
Let's turn to some practical examples. These
charts are readings taken from a finished gear
M ajor Axis Radius 8.31 IS mm. Minor Axis Radius 4.1859 mm

Delq
Rpk
1.0600 Mm
Ra 0.8758 Mm
6.6218 deg
Rvk
Lamq
1.1497 Mm
Rq 1 0893 Mm
149.4679 Mm
RzlSO
M rl
Rp 2.7351 Mm
4.7760 Mm
10.0000 *
Rv 2.8244 Mm
Rpm
Mr2 8 8 .0 0 0 *
2.2128 Mm
Rt 5.5595 Mm
R3v
Sm 151.2853 nm
4.0506 Mm
Rsk 0.0696
R3*
2.9999 Mm
4.7649 mm
Lo
Rku 2.6463
2.8948 Mm
MORE ...
Rk
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Raw Data
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with an cngineering-quality metrology instru

Options
ment. Raw data from the surface o f a gear tooth

was taken from the root out.
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Fig. 2
Fig. 1. The surface with the circular form

removed. The result combines roughness and
waviness. The data was acquired with a diamond
tipped stylus having a 0.00008" radius.

Bearing Ratio and Amplitude Dist.

Rough/Gauss/6 0.8mm. 100: I/Ellipse
Amplitude Distrib' n
Fig 2. The result of low distortion filtering to

remove the long wavelengths of waviness. The
Bearing Ratio
commonly used parameters arc calculated.

Fig. 3. This is an examination of the amplitude
distribution and the bearing ratio curves. Here is
where we will find the description of multi-pro
cessed surfaces. Both of these analyses are a
summary of the surface examined. Amplitude
distribution is the number o f events vs. height
from the top of the trace to the bottom. This
analysis could be used to limit the number of
peaks or valleys at a specific amplitude. Bearing
ratio is the length of the surface vs. height ex
Fig. 3
pressed as a percentage. This analysis could be used

to limit the width of the peaks or mandate the width
o f the valley indirectly controlling their volume.
Fig. 4. This figure shows the Rk parameter with
an evaluation of the bearing ratio curve. This
analysis was developed to characterize the multi
processed surface o f the cylinder bore of an inter
nal combustion engine. A similar approach may
be applicable to gears. The parameter is used to
control the amount of debris during breaking, the
height of the core load bearing surface, and the
ability to retain lubrication. Note that each area of
interest is described numerically.

Results Page
2.500 nm "
-2.500 Jim J
Fig. 5. This chart shows the analysis of the low

W ave/Gauss/6 0.8mm/Ellipse
frequencies of waviness. The significant param

Beanng Ratio/
Amp distb.
M odified Profile
eters have been calculated.

Our discussion has concerned the metrological
needs of the manufacturing process and its control.
414.2 |lm
The investigative scientist may use other analysis

Major Axis Radius 8.2328 mm. Minor Axis Radius 4.1292 mm
Delq
1.0180 nm
Wa
0.2475 deg
Wq
Lamq
1.6826 mm
1.1569 pm
Wp
Wpm
1.9082 Mm
0.9097 Mm
Sm
Wv
2 .1859 ^m
3.0584 mm
Wt
4.0941 Mm
Lo
4.7588 mm
-0.3019
Wk
Wku
1.7216
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Fig. 5
Presentation
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Raw Data
Selection
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procedures to evaluate subjects of interest. These

may include the effect of peak height vs. lubrication
Options
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thickness or peak area vs. stress. The modem

surface texture measuring instrument is a versatile
engineering device for roughness, waviness. form,
and size, and because of its power and precision, it
is applicable to more scientific studies as well.
$u. Ui At.
QEI
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Man has been using the same spline gage ever since. Thatis, until
FRENCO redesigned the gage for modem man. The Frenco indicating
spline gage produces vanable data on exact Pitch Diameter while
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also quickly checks taper, ovality and other time consuming inspections.
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Deburring Solutions from
M odular design allows flexible customizing

Compact size is ideal for cell environm ents
Quick easy setups make short runs practical
Substantial p ro d u c tsity im pro\cm cnls over
conventional methods
Keduction of scrap rates
Autom ated part handling systems available
A ttachm ent options for all gear configurations
Systems for irregular part shapes
Dust control enclosures
MIL Spec deburring control
The James Engineering modular deburring systems can be set up in less than one minute, with cycle times of 20 to SO seconds
per part. Manual loading and unloading barely takes S seconds, with fully automated systems available. Precision controls allow
edge break of uniform quality and consistency from pan to part and from ,(X)I" radius to large chamfers. Modular design allows
modification of system as needs change. Due to the compact size, the system may be placed near hobs or shaper cutters, allowing
operators to deburr the gear while demanding very little of their time or attention. This allows shops to either eliminate or
drastically reduce secondary handling and conventional deburring steps. This significant reduction in labor, along with a lower
scrap rate, means big dollar savings to the user.
Jam es E n g in e erin g 4732 P earl S tre et B o u ld er. C O 80301 (3 0 3 ) 4 4 4 -6 3 3 7 Fax (3 0 3 ) 444-6561
1 J
GEAR FUNDAMENTALS
Introduction to
Worm Gearing
James K. Simonelli
JKS & Associates,
Brecksville, OH
Worm gears are am ong the oldest types o f
tion for m ost a p p lic a tio n s , and o th e r form s
gearing, but that does not mean they are obso
o f gearing should be considered. W orm g e a r
lete. antiquated technology. The main reasons
ing for ratios above the ranges m entioned are
for the bad experiences some engineers have
generally m ore practical as part o f a m u lti
with worm gearing are m isapplication and
stage reduction.
m isuse. No form o f gearing w orks for every
In service, worm gears survive large over
application. Strengths and w eaknesses versus
loads and high shocks. W hen properly ap
the application must be w eighed to decide
plied, worm gearing can offer excellent per
w hich from o f gearing to use. For proper
form ance and cost savings. W orm gearing has
application and operation o f worm gears, ce r
an inherent 200% overload (i.e., 3x rating)
tain areas that may d iffer from other types of
capacity in its rating. O ther form s o f gearing
gearing need to be addressed.
do not have this built-in service factor. T here
T he Basics
W orm gear reducers are quiet, com pact,
fore w hen sizing a worm gear set. a low er

service factor than normal can be used.
and can have large reduction ratios in a single
E x p la n a tio n o f H and
stage. The ideal ratio range fo r w orm g e a r
The purpose o f left- and right-hand gearing
ing is 5 : 1 to 7 5 :1 . T h is is the g e n eral range
is to change the relative rotation o f the worm to
for m ost c a ta lo g re d u c e rs. R atios o f 3:1 to
the gear. Hand refers to the direction o f axial
120:1 are p ra c tic a l and have a p p lic a tio n s
thread movement as the worm is rotated. If you
th at are very su c c e ssfu l. F o r ra tio s below
point your thumb in the direction o f axial m ove
3 :1 , w orm g e a rin g is not a p ra c tic a l s o lu
ment and curl your fingers in the direction o f
Axial Movement
Axial Movement
Worm Thread
Worm Thread
Left Hand
Right Hand
Fig. 1 - Comparison of left and right hand.
rotation, the hand that corresponds to the worm

Right
Hand
Left
Hand
is the hand o f the gear set. (See Figs. I&2.)

Bolts are a sim ple exam ple. Norm ally they are
right-handed, and experim enting with a nut and
bolt will help to clarify this description.
Right-hand gear sets, like bolts, are the
industry standard. More right-hand gear ratios
are available as standard items, and most m anu
-3 -
It
is a flaw in left-hand gearing, but left-hand

ratios may not be as readily available.
B ack D riving
A
CW Worm
CW Gear
CW Worm
CCW Gear
A,
facturers will supply right-hand gearing unless

otherw ise specified. This does not mean there
U (?1Sv
zJ
CCW Worm -
CCW Gear
CW Worm
CW Gear
CW Worm
CCW Gear
CW Worm
CW Gear
Running a worm gear set with the gear

(w orm w heel) as the input m em ber is com
m only called hack driving. Back drive e ffi
ciency o f a worm gear set is low er than its
9.
forw ard drive efficiency. By varying design,

the back drive efficiency can be reduced to
zero, as in a self-locking or irreversible gear
set. If the gear tries to drive the worm, internal
CCW Worm 4
CW Gear
CCW Worn
CCW Gear
friction causes the mesh to lock. No m atter how

much torque is applied to the gear shaft, mesh
friction increases proportionally, preventing
rotation. This is the same principle that keeps a
Fig. 2 - Relative rotations.
nut and bolt from unscrew ing under an applied

Worm Gear Back Drive Efficiency
Efficiency vs. Rubbing Velocity
tension load.
Back driving can occur in many applica
Various Lead Angles
tions. A worm gear speed increaser is the most

obvious, but it is rarely used because o f its low
efficiency. It also occurs in lifting applications,
such as cranes, hoists, and crank arms. When
low ering the load, the gear is the input member.
W orm rotation controls the rate o f descent.
Also, during braking or coast-dow n, the m o
m entum o f a device will back drive a worm.
A self-locking worm gear can be designed
by m aking the lead angle less than the frictio n
angle, which is defined as the arc tangent o f
the coefficient o f friction. The static co effi
cient o f friction is .20 to .15. equating to a
Rubbing Velocity (fpm)
friction angle o f 1 1.3 to 8.5. V ibration in a

non-rotating gear set can induce m otion in the
tooth contact. T he m esh velocity is zero, but
Fig. 3 Worm gear back drive efficiency.
gear will back drive.
the tooth co n tact is dynam ic. Ai a m esh ve
Back drive efficiency decreases with de
locity o f zero, the th eo retical d y nam ic c o e f
creasing speed. The slope o f this curve is expo
ficient o f friction is .124. o r a frictio n angle
nential and is affected by the lead angle. (See
o f 7.0. To provide a safety factor, a 5.0 lead
Fig. 3.) This factor should be considered when
angle is recom m ended as the upp er lim it o f
sizing a brake and its rate o f application. Often
self-lo ck in g , and a 15.0 lead angle is reco m
a brake placed on the worm can be sm aller than
m ended as the low er lim it to assum e a worm
normally anticipated. Self-locking worm gear
James K. Simonelli,
P. .. is a p o w e r tra n s
m issio n co n su lta n t. He
has o v e r ten y e a r s ' ex p e
rience in p ro d u c t d esign
a n d tro ublesh tm tin g with
a p p l i c a t i o n s r a n g in g
fr o m sm all co n su m er a p
p lia n c e s lo la rg e ste el
m ill drives.
1 J
35
sets will coast because o f dynam ic effects.

Using a brake on self-locking designs must
be thoroughly analyzed. Most brakes have an
or "roller" clutch and is com m only used on

conveyors that lift material to prevent reversal
if pow er is lost.
increasing torque rate when applied. Also, the
Plugging" is a m ethod o f braking gener
efficiency will be decreasing during slow down.
ally used in large crane wheel drives that use
This double effect can cause the effective brak
reversal of the drive motor. Plugging applica
ing torque to rise at a surprising rate, causing
tions can cause extrem ely high torque spikes.
a sudden stop. High inertial loads with self
The worm system inertia consists o f the worm,
locking designs should have controlled motor
drive motor, and any m iscellaneous com po
speed ramp down for braking.
nents. The gear system inertia consists o f the
On the other hand, back drive efficiency
gear and the entire braked device. When plug
increases with increasing speed. Therefore a
ging, the worm can reverse rotation before the
constant back driving torque restrained only by
drive train loads in the back drive direction.
a worm gear will have a rate of acceleration (hat
The worm system s momentum is in a direction
increases exponentially. This is a very im por
opposite the gear system. At impact, the worm
tant point to rem em ber when designing hoists.
must again reverse rotation to follow the gear,
Unless it is properly designed, relying solely on
crossing a point where the mesh rubbing veloc
self-locking m echanism to suspend a load may
ity is zero. The gear system s momentum will
be dangerous. The load may stay suspended
generate w hatever torque spike is required to
until an outside influence starts a vibration in
force the worm to reverse rotation and over
the gear mesh. At first, the load will creep
come the m otor plugging torque and the mesh
slow ly. As it falls, it accelerates at an ex p o
back drive efficiency at zero speed.

Torque spikes are a transient im pact effect
n entially increasing rate.

Since many factors influence the coefficient
and not a problem when the system is properly
of friction, gear set designs should be tested for
designed. Plugging designs should limit the use
their back drive suitability. Break-in of a gear set
o f brittle m aterials, such as grey cast iron.
will reduce the coefficient o f friction. This may
Bolted joints and drive train m ountings should
make a gear set self-locking when it is new and
be designed for impact. In wheel drives, the
not self-locking after use. Also, synthetic lubri
wheel slip torque lim its torque spike and can be
cants can have an effect on the coefficient of
used as a maximum design point. Peak torque
friction and may be used in the field without the
can be reduced by slowing the rate o f reversal.

C o n tac t P a tte rn
know ledge o f the gear designer.

If self-locking is critical to safety, a brake or
The area o f contact the worm m akes on the
back slop" should be used. A back stop is a
gear as it rotates into mesh is the contact p a t
clutch device that perm its rotation in one direc
tern. The ideal contact pattern for worm gear
tion only. It is sometimes referred to as a "Sprag
ing uses 90% o f the full face, with the remain-
Flanks Show Contact From Bi-Directional Operation
Entenng
Side
Entenng
Entering
Leaving
Leaving
Leaving
Side
Side
Leaving
Side
Entering
Side
4a - No-Load
Fig. 4 Typical contact patterns of a worm gear set.
4b - Full Load
4c - Overload
ing 10% open on the entering side (Fig. 4b).

This has m aximum area for load distribution
Shim to adjust bearing
and still allow s oil to be dragged in for lubrica

tion. If the entering side has contact, (Fig. 4c)
the oil would be w iped o ff the worm as it rotates
into the gear. W ithout oil being draw n in. the
gear set will not generate an oil film and will
quickly fail. (See the section on lubrication for
more details.)
Under load the gearbox, worm , and gear
will deflect. These deflections cause the co n
tact pattern to spread across the gear face to
ward the entering side. To com pensate for con
5a
tact pattern spread, the gear can be moved

axially in relationship to the worm. This will
increase the open face at no load (Fig. 4a), so as
Shim to adjust bearing end play
not to close o ff the entering side at full load. A

no-load pattern o f approxim ately 30% o f full
face on the leaving side is desirable.
Shim to adjust gear contact
Since deflections occur in opposite direc

tions for opposite rotations, the tw o flanks o f a
gear tooth cannot be directly in line. The flanks
need to be shifted axially with respect to each
Gasket
other when the gear is cut. The axial movement

o f the gear required for the contact pattern to go
from 90% full facc to 90% full face on the
opposite tooth flank is the total shift. Total shift
anticipates deflections that will occur from full
load forw ard to full load reverse.
The no-load contact pattern is determ ined
by lightly coating the worm threads with Prus
sian Blue (i.e., high spot blue). This transfers to
the gear teeth when rotated by hand. Although
not required, coating the gear teeth with a
m ixture o f pow dered orange paint pigm ent and
Fig. 5 - Typical gear shaft assem blies.
grease makes the pattern easier to see. The
tion loading, such as hoists or conveyers, shift-
orange grease paint im proves the contrast of
cut into a gear is not a m ajor concern. Since the
the blue transfer pattern and adds lubricant to
opposite flank is never loaded, the pattern is
the mesh. To observe the contact pattern under
adjusted on the drive flank only, ignoring the
loaded conditions, a coat o f layout blue can be
non-drive flank. W hen adjusting the gear to
sprayed on the gear teeth. This will quickly
favor one flank, care must be taken so that the
w ear off, revealing the full load contact pattern.
gear does not lose all o f its backlash. If this
Be sure the surface is oil-free when spraying
happens, the worm is w edged into the corner
and w ait until the blue dries before operation.
o f the gear. This will generate excessive heat
Oil may wash the coating o ff if it is not com
and cause prem ature failure.
pletely dry.
In most reducer designs, axial gear adjust
In severe applications under heavy loads,
ment is accom plished by shim s placed between
the fully loaded pattern should be checked.
the gear shaft bearing caps and the housing
The am ount o f shift cut into a gear may not
(Fig. 5a). First, determ ine the total shim stock
com pensate for an overly flexible housing or
for proper bearing end play. Then transfer shims
higher-than-anticipated loads. For one d irec
from one side to (he other until an optimum
pattern is obtained. In heavy duty applications
The break-in process is the gear tooth form
where one would like to adjust the gear fully
being im proved by the worm. T his is done by
loaded, m oving shims requires disconnecting
elastic or inelastic deform ation, w earing away
the shaft couplings, rem oving the gearbox from
the high spots or pitting them away. A fter the
its m ounting, and rem oving the gear shaft cou
many high spots are either worn or pitted
pling. This is a very difficult process in large
away, the worm rides on the larger fiat areas.
m achinery. A com m on method to adjust the
The pit areas retain pools o f o il, w hich help
gear from one side is to put both thrust bearings
support the load by hydrostatic pressure and
in a carrier on one side (Fig. 5b). The opposite
aid in lubrication. C orrective pitting ceases
side is supported by a radial bearing that is free
after a sufficient area has been dev eloped to
to move axially. There are other methods of
sustain the load and norm al w ear takes over.
adjustm ent, but these are the most common.
A new worm gear will pit at an alarm ing rate,
P ittin g
then quickly stop. No additional pitting will
G ear tooth pitting results from the com bina
o ccur for a long tim e. Then the surface will
tion o f several forces. Normal force (referring
again pit rapidly and quickly stop, the cycle
to a direction 90 to the tooth surface) at the
recurring throughout the life o f the gear.
contact point produces Hertzian stress. Friction
D estructive pitting is a case o f the gear not
produces a tangential force, which induces sub
being able to correct itself enough to support
surface shear stress. Friction also generates
the im posed load. It is the result o f overload,
heat. T em perature at the contact point is much
im proper gear adjustm ent, im proper tooth pro
higher than the surrounding area. Differential
file, or im proper lubrication. In this case, pit
thermal expansion (the phenom enon that can
ting continues until the gear tooth surfaces are
cause a glass to break when a hot liquid is
com pletely destroyed. T his is not a com m on
poured into it) induces stress.

C onstant cycling as the tooth goes through
the m esh can cau se a surface fatigue crack.
Oil in the gear mesh is under extrem e pressure
problem , because most errors large enough to

cause failure will norm ally show up as the
gearbox overheating.
M a te ria ls
from contact forces. The oil is forced into the
W orm gearing has a high sliding com po
fatigue crack, and hydrostatic pressure tries to
nent in its tooth m eshing action. Sliding co n
lift a piece out. C ontinuing cycles cause the
tact m aterials are selected to make one m em
crack to encircle the high stress area. The
ber hard and strong and the other soft and
crack grow s deeper, until a piece literally pops
ductile. Friction is g enerally proportional to
out. leaving a pit.
the com bined hardness o f the m ating su r
In m ost gearing, a pitted tooth surface
faces. Tw o hard surface cannot deform to
signals im pending failure. For worm gearing,
broaden the contact area and distrib u te the
pitting is part o f norm al operation. C orrective
contact stress. By hardening only one part
pitting is a break-in process. In m anufacturing
and having the o ther d uctile, the com bined
a w orm , the thread is generated by a c o n tin u
hardness is increased, w hile still being able
ous line that can be d escribed by the grinding
to d istrib u te stress. A lso, using d issim ilar
w heel. It produces a continuous (i.e.. sm ooth
hardness reduces the chance for galling. Steel
and u n ifo rm ) su rface curved in all three
and bronze have been the m aterials o f choice
planes. T he g ear is hobbed by a gashed c u t
because they balance strength, d u c tility , lu
ting tool that is in effect a worm having a
bricity. and heat d issipation. Shaft bushings
discontinuous or interrupted surface. It pro
are com m on exam ples o f sliding com ponents
duces gear teeth which have a series o f short
using this arrangem ent.
flats or discontinuous surfaces that approxi
The worm is the hard m em ber, and the gear
mate the desired tooth form. Because o f the
is the ductile m em ber. There are several rea
flats, the gear tooth form is im perfect. W here
sons for this arrangem ent. C ontact stress in
tw o flats jo in there must be a peak. At such a
both m em bers is equal. The worm goes through
point, the contact street would be infinite if
more contact cycles because o f the ratio o f the
deform ation did not occur.
gear set. C om pared to steel, bronze has a
low er strength, a low er endurance ratio, and a
m ation to d istrib u te stress. A sim ple m odel
higher num ber o f cycles required for infinite
w ould be to picture m arbles (delta phase)
life. Fig. 6 uses these factors in a generalized,
im bedded in clay (m atrix).
theoretical S-N curve. Stress levels that have
A lternate gear m aterials may increase c er
a finite life for bronze w ould have an infinite
tain properties, but losses in others will tend
life for steel. Since the bronze will fail at a
to m ake them unsuitable for general use. For
few er cycles, it is used for the m em ber requir
special ap p lications bronze alloys other than
ing the few est cycles.
tin bronze may perform better. G ear m ateri
G ear mesh reaction forces are equal and
als, such as cast iron, plastic, and even steel,
opposite in both m em bers. The worm is much
have w orked very well in certain ap p lica
sm aller in d iam eter than the gear and has a
tions. Each application m ust be thoroughly
greater span between supports. Therefore bend
analyzed by a gear eng in eer before selecting
ing stress is greater in the w orm , requiring it to
alternate m aterials.
be m ade from the stronger m aterial.
W orms are generally made from an alloy
M anufacturing m ethods also play a part in
steel. Steel w orm s can be divided into hard
m aterial choice. G rinding is generally used
ened and non-hardened. H ardened worm s are
for accurate finish o f high-hardness, heat-
superior in m ost applications. W hen surface
treated steels. G rinding the worm is a sim ple
hardness of approxim ately 58Rc is used, sev
process, using the flank o f a straight-sided
eral benefits are gained. M aterial strength is
grinding w heel. G rinding the gear requires a
increased, friction is low ered, and w ear is
com plicated process using a form dressed
reduced. Often a worm can be reused after the
grinding w heel and a three-axis grinder.
gear has worn out.
Tin bronze has proved to be the most suc
N on-hardened refers to the surface being
cessful alloy for worm gears. It has a low
low er than the typical 58 R . N on-hardened
coefficient o f friction and a low rate o f wear.
w orm s may actually have a heat treatm ent to
Good heat conduction carries aw ay heat gen
bring up the core hardness for increased strength.
erated in the m esh and dissipates it throughout
In industrial applications, a core hardness o f
the gear. A lum inum b ro n zes have h ig h er
300 Brinell is typical. N on-hardened w orm s
strength, but also a higher coefficient o f fric
are useful in ap p licatio n s w ith low co n tin u
tion. A less obvious disadvantage o f the higher
ous pow er and very high peak or shock loads.
strength alloys is low er ductility. T heoretical
T hese applications are most often m achine
contact betw een a worm and gear is a line. In
adjustm ents or m echanism s that are infre
practice, the bronze d eflects under load broad
quently activated. Heat treating for increased
ening the contact line to an area. The m aterial
surface hardness may be elim inated in low
deflects until the contact area broadens enough
pow er applications to decrease cost. If a worm
to support the load. A low -ductility m aterial

may have localized failure before reaching a
large enough area. Sm all contact areas o f a
low er ductility m aterial have higher localized
contact tem peratures, w hich further increase
the sub-surface stresses.
The unique p ro p erties o f tin bronze can be
traced to its grain stru ctu re. W hen the bronze
so lid ifies, p artial seg reg atio n o f the cop p er
and tin o ccurs. High tin areas o r g rain s are
com m only called the d elta phase. H ardness
o f the d e lta phase is a p p ro x im a te ly 320
B rinell. The high co p p er m atrix supp o rtin g it
is ap p ro x im ately 145 B rinell. The hard g rains
provide w ear resistan ce and help reduce fric
tion. T he so fter m atrix allow s surface d e fo r
Fig. 6 - Generalized theoretical S-N curve.
is used w ith a cast iron or steel gear, it should
tact tem peratures. Under high loads the film
be non-hardened.
can collapse, causing the surfaces to contact.
B ack lash M e asu rem en t
This is called "boundary lubrication. In this
B acklash is the m easure o f the free c le a r
lubrication mode, other properties (i.e., lubric
ance betw een the worm and the gear teeth.
ity or slipperiness) o f the lubricant becom e
M easurem ent is done by locking the worm
more im portant than the viscosity. In a worm
against ro tatio n , setting a dial indicator on a
gear set, a m ixture o f EHL and boundary
g ear tooth at the pitch radius, and rocking the
lubrication are at work.
g ear back and forth. The total indicator read
A satisfactory lubricant for most average
ing is the m easurem ent o f backlash. L ocking
applications is a AGM A 7 com pounded oil.
the g ear and m easuring worm rotation does
Low speeds require the higher viscosity o f
not m easure backlash. In an assem bled unit
AGM A 8 com pounded oil. Both are p e tro
w here the g ear teeth are not readily a cces
leum based m ineral oils com pounded with
sible. backlash can be approxim ated by p lac
3% to 10% fatty oils. T hese lubricants are
ing the indicator on any convenient point that
som etim es referred to as steam cy lin d e r oils.
is fixed to the gear, such as a shaft key way or
The com pounded oil provides low er friction
coupling. T his m easurem ent must be m u lti
and b etter w ear ch arac teristic s than a straight
plied by the ratio o f the gear pitch radius to
m ineral oil. At the high pressures and tem
the m easurem ent radius. N ote that if the se
p eratures in the contact area, a chem ical reac
lected point is on the radius sm aller than the
tion occurs on the tooth surface, form ing a
pitch radius a m ultip lication o f m easurem ent
protective skin.
Extrem e pressure oils (EP oils) are another
e rro r will occur.

Backlash =
type o f lubricant that uses a surface acting
(M easurem ent) x G ear Pitch Radius
chem istry. M ost EP oils use sulfur, phospho
M easurem ent Radius
rus. and/or chlorine additives, and are d e

signed to work in steel-on-steel applications.
L u b ric a tio n
W hen these oils are used with bronze under
W orm gearing has a high slide-to-roll ratio
high tem perature and pressure, conditions com
when com pared to other types o f gearing.
mon in the mesh contact, the chem ical reac
B ecause o f a high sliding com ponent, it relies
tion can go aw ry. The surface o f the bronze
heavily on the g eneration o f an oil film b e
can begin to flake off. causing m assive wear,
tw een the worm and gear. The oil film pro
and intergranular stress corrosion can cause the
duces an effect sim ilar to w hat happens when
teeth to break. There are EP oils designed for
a speeding car hits a rain puddle. The car tire
use with bronze that use a different additive
has a tendency to float on a wedge o f w ater.
package, and in certain applications a standard
In a car this is called h ydroplaning; in gears it
EP oil may work very well. W hen selecting a
is called e la sto -h y d ro d y n a m ic lu b ricatio n
EP oil for bronze gearing make sure it was
(E H L ). T his is a sim p listic description with
carefully reviewed.
o th er m odes o f lu brication com ing into play,
Synthetic lubricants are also very co m
d epending on co n d itio n s, but it gives the
mon. They are m ore viscosity-tem perature
general idea.
stable than m ineral oils. T his allow s one lubri
For EHL to be the only lubrication mode, it
cant to provide adequate service over a broader
must generate a film thickness greater than the
tem perature range. They have longer service
surface roughness o f the contacting parts. Film
life, reducing the num ber o f oil changes re
thickness is proportional to the sliding velocity
quired. They reduce w ear and friction, in
and lubricant viscosity and inversely propor
creasing gearbox life. Efficiency increases o f
tional to the unit load. High unit loads possible
20% o f the lost pow er are possible. U nder
at the relatively low speed o f worm gearing
severe conditions properly selected synthetic
requires a very high viscosity lubricant. V is
oils are outstanding. M any com panies have
cosities o f over 400 cSt at 40C are normally
found cost advantages using the more ex pen
used to prevent prem ature w ear and high con
sive synthetic oil for norm al applications.
Getting Started in
Exporting
Nancy Bartels
xporting. Its one o f
sh o u ld be looking into ex
the hot strategies for
p o rtin g now , o r is th is ju s t
helping boost busi
a m y th ?
nesses o f all kinds,
RN : You have to ask
gear m anufacturing among

some fundamental questions
them. With dom estic mar
about your company, and.
kets tight and new markets
depending on the answers,
opening up overseas, export
maybe the overall conclu
ing seems like a reasonable
sion will be that exporting is
tactic. But while the pres
not going to be an appropri
sure is on to sell overseas,
ate match. But having said
there is equal, justifiable con
that, its important to remem
dont even try. The fact is
cern about whether the move
ber the statem ent by Ken
that getting into exporting is
is a good one. Horror stories
Butterworth, the Chairman
not nearly as complicated,
abound about foreign restric
o f the Board at Loctite Corp..
time-consuming, or expen
tions. bureaucratic snafus,
a m anufacturer of adhesives
sive as most people think.
carloads of paperwork, and
which exports about 65% of
G T : W h at a re the kinds
the com plications and nu
its product. He says, the big
of questions a gear m a n u
ances o f doing business in
gest non-tariff barrier to U.S.
fa c tu re r should be asking
other languages and with
exports is the attitude of the
before m aking the decision
other cultures.
CEO ." A lot of people start
to ex p o rt?
Is e x p o rtin g re a lly a
off with the perception that
RN: First, you should be
sound approach to com peti
I cannot export my prod
asking (he basic marketing
tiveness in the 90s? T o find
questions. Is there a market
n o lo g y talk ed with Rick
uct." and, therefore, they

a
Norment. form er executive
the an sw er. G e a r T e c h
director o f AGMA and now

the president o f Norment &
Associates, a consulting firm
in Falls Church. VA, that
specializes in trade and com
p etitiv en ess dev elo p m en t
non-tariff
exports is
m anufacturers.
I barrier toU.S.
for precision com ponents

G T : L e t's begin w ith
Thebiggest
>
theattitude of
the CEO.
Managing a business
today is hard work. Let
" Manag eme nt M a t
ters" lend a hand. Tell
us what management
matters interest you.
W rite to us at P.O. Box
1426, Elk Grove, IL
60009, or call our staff
a t (708)437-6604.
for this product in the coun

try in which I wish to sell it?
Can I sell co m p etitiv ely
there? Can I sell for less
than the local suppliers or
for the same price with bet
ter quality?
The dramatic shift in ex
change rates over the last
couple o f years have really
been to our advantage here.
Because the dollar has been
th e very b asic q u estio n . Is
substantially devalued and
it t r u e t h a t e v e ry b o d y
many other currencies have
Rick Norment
is the p re sid e n t o f N orm en t
A A sso c ia te s, Inc.. F a lls
C hurch. VA. a co n su ltin g
f ir m s p e c ia liz in g in g o v
e r n m e n t r e la tio n s a n d
tra d e a n d c o m p e titiv e n e s s
d e v e lo p m e n t f o r p r e c isio n
c o m p o n e n ts m a n u fa c tu r
ers. H e is a ls o fo r m e r E x
e c u tiv e D ir e c to r o f th e
A m e ric a n G e a r M a n u fa c
tu re rs A sso c ia tio n .
1913
risen, the price equation is j are matters like: What kind
zero exports to 30% o f your
evaluate it for your product,
much more competitive now.
o f trade restrictions does this
product in the first year.
your niche. It's back to those
Grow slowly.
old questions: Can you be
Another basic question to
country have? W hat about
ask is: What is the average
tariffs? What about certifi
size o f the order w ere talk

ing about? If you 're talking
Make the decision about
competitive on price? Is there
cation requirem ents? What
which countries to enter on a
a barrier for getting into the
other countries are in there
rational, not an emotional
m arket? Can you get easy
about o rd ers o f $500 or
trying to sell the same kinds
basis. For example, in the
access to it? Can your cus
$1,000 or even $10,000. it
o f products?
past couple o f years, there's
tom er pay you?
could be difficult to turn a
Also ask about in-coun
been this gold-rush m ental
GT: It sounds as though
profit. But rem em ber with
try capability and com peti
ity about Central and East
e\|M)rting requires a lot of
gears, the price o f the order
tion. It always amazes me
ern Europe. People say. "Gee
prep aratio n , research, and
is frequently m easured in
how someone will say. I'm
whiz, my grandparents were
fact finding before you even
hundreds o f thousands o f
going to sell these gears in
from Poland, so le t's go to
get into it. How difficult is it
dollars. In a case like that,
Germ any." Well, that's a re
Poland." Poland may not be
to get the kind of inform a
a bad choice, but you have to
tion youre talking about?
theres enough o f a differ
ally tough market. They have
ential as a result o f the ex
a powerful domestic market
change rates to make export
already and a strong tradi
ing quite feasible.
tion of preferring German-
GT: Is there such a thing

as a company being too small
m ad e
p ro d u c ts .
U n le ss
you've got a significant qual
RN: No. I know o f gear
thats a very tough sell. It's
companies with as few as 30
not impossible, of course, but
employees who have rather
there are other markets that
significant percentages o f
are a lot more accessible.
their total sales in exporting.
Most of the other factors
Its the size o f the order, not
that inhibit companies from
the size o f the company that
getting involved with export
makes the difference. If your
ing are mental. 1always coun
company is big enough to fill
sel people to proceed with
the order, then you're big
caution, and that's something
enough to export it. Sixty-
that you can do with export
four percent of all products
ing. Start small. Do some
exported from the U.S. come
exploration first. Look at the
from manufacturers with less
market, get a sense for it. talk
than 500 employees.
to potential customers, find
G T : W h at o th e r things
do you have to consid er?
RN: A ctu ally , this is
this particular country?

2. Can I sell the product for less than
the local suppliers or for the same
price with better quality?
3. What size orders can I reasonably

expect to be filling?
might be surprised at the an

swers you get.
For example, its logical
should be asked first: How
to look to Mexican and Ca
am 1 going to get paid? This
nadian exporting. These are
is not alw ays a sim ple yes-
close-by countries. Getting
or-no m atter. But you c e r
across the border is much
tainly need to know if you
simpler; so are the customs
can get a certified letter o f
and shipping regulations.
credit from a custom er, or
Once you find you can ex
is he going to want to barter
port to Canada or Mexico
or w hatever. T h a t's abso
and make a profit at it. then
lutely crucial.
maybe you want to expand a
Other things to consider : little. But d o n 'ttry to go from

T E C H N O L O G Y
1. Is there a marketforthis product in
out what their prices are. You
m aybe the q u estio n that
GEAR
Export Checklist
ity and price differential,
to export?
42
M ANAGEM ENT MATTERS
4. What kind of import restrictions

does this country have?
5. Who are my competitors in this
particular market?
6. How am I going to get paid?
How expensive is it?
to get a sense for your m ar
RN: Not nearly as ex
ket. You may have a couple
pensive as you might think.
o f false starts. T he first
in one
You can find out what you
couple o f countries you look
GEAR
need to know to enter a par
in to
S O F T W A R E
m ay
n o t be g o o d
ticular market for as little as choices, but in the end you' II

$10,000. And that price will
find the right niche.
include the cost o f gaining
G T : A nd w h ere does
the necessary inform ation,
one find th is in fo rm atio n ?
having somebody assist you
R N : T wo of the most use
to analyze it and focus it spe
ful resources are your state
cifically to your company
and federal governm ents.
and product needs, help de
They will give you lots of
velop some o f the contacts
g u id an ce and a ssistan ce.
that need to be made, and the They have access to infor

plane ticket for the first trip. : mation about countries all
You certainly d o n 't need to : over the world. Find your
hire a Vice-President o f In- j local office o f the U.S. For
G T : A nd how
How does it w o rk ?
diseng v l.l
Is the first gear design
software that really designs
and not just calculates.
FIR S T
Y ou define for each
param eter, such as ratio,
center distance, pressure
angle, etc., a convenient
set o f values that you are
really able to use.
diseng v l.l
Is really easy to use in your
PC, because it permits
achieving high performance
results since it is also a
research tool for analyzing
the influence of each single
param eter variation
in the results.
SEC O N D
Y ou d efin e y o u r p e rfo r
m ance n e ed s re g ard in g
P itting L ife, B en d in g L ife.
S co rin g P ro b a b ility ,
R eliab ility L evel and
O p eratin g C o n d itio n s.
diseng v l.l
Also has preliminary
dimensioning program
presented as a spread sheet.
T H IR D
eign and Commercial Ser
ternational M arkets.
lo n g vice or your state office of
d o es th is k in d o f in fo rm a- : e c o n o m ic
tion g a th e rin g ta k e ?
d e v e lo p m e n t.
Most m ajor metropolitan ar
RN: If youre going to
eas have one or both of these.
make a focused, intense ef
These are the people to talk
fort. you can do it in as little
to. They know the countries.
as eight weeks. In that period
They know the nam es o f
of time, you can get a suffi
m ajor players, etc.
DESIGN
You w a it a few seco n d s

until d ise n g finds out the
b est so lu tio n w ithin y our
p a rticu la r p o ssib ilities.
diseng v l.l
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Technical Support in the USA and Canada:
THE DUDLEY TECHNICAL GROUP. INC.
Gear Systems Consultants
17150 Via Del Campo. Suite 308
San Diego. California. 92127-2139 USA
Phone <l-X(M 354-5178 Fax (619) 487-4X93
"Demo & Full Demo

Disk Available"
C IRCLE A-16 on READER REPLY CARD
cient sense o f the m arket
Be aware, however, that
place. find out whether or
the inform ation you get from
not y o u 'v e got any real shot
the governm ent is going to
at it. It can. of course, take
be pretty general. Theyre not
GEA R TE C H N O LO G Y
longer. M ajor corporations
going to know the gear in
is looking fo r a few
good pens.
may have hundreds o f people
dustry specifically, so you
doing analysis for six months
may want to also consult with
before they make a move to a
someone who is familiar with
particular country, but when
the industry as well.
'
r e l o o k in g f o r n e w
M A TERIAL O N A LL A SPECTS O F
they go in. they 're talking
G T : Once a company has
contracts of hundreds o f m il
made the decision to go into a
G EA R D E SIG N , R E SE A R C H ,
lions o f dollars.
country, what other kind of
M A N U FA C T U R IN G , AN D
Im a big believer in the

KISS method. Keep it short
resources does it have to have

in place?
D E V E L O PM EN T.
is
I f YOU HAVE
AN ARTICLE Y O U D LIK E TO
and sim ple. T h eres no hard
RN: You need a way to
and fast rule about how much
get the orders. While you can
tim e or money this inform a
send a salesperson into the
tion gathering will take, but
country, that generally is not
I think you should start off
cost-effective. The best way
A sk fo r a copy o f o u r
with the expectation that this
is to find a m anufacturers
W r i t e r 's G u id e lin e s .
is going to be som ething that
rep or distributor for your
requires a little bit o f effort
product. Again, either gov
and money. As I said be
ernm ent or private sources
fore. go slow. Take the time
are available to help you find
SH A R E OR AN IDEA FOR AN
A RTICLE Y O U D LIK E TO D ISCU SS
W ITH O N E O F OU R E D IT O R S,
c a ll
us
a t
(708) 437-6604.
1993
the right person. Make a trip
G T : H ow d o you go
ing to export to Bosnia these
the factory level. Or he'll be
over to interview several
a b o u t e v a lu a tin g th e se
days. I mean, think about it.
there, but h e'll have a differ
candidates. Visit some m a
p eo p le? How d o you know
Does the Bank o f Bosnia
ent job. You have to rem em
jo r prospective custom ers
th e y re an y good?
have any money? Can a buyer
ber that in these countries,
and train the rep all in one
RN : This you handle just
get money out of the coun
th ere's a whole couple of
shot. By having an in-coun
like you would getting any
try? Can you get goods in?
generations who dont know
try contact working for you
other kind o f vendor. Ask for
Somehow I doubt it.
how to do business outside
all the tim e, y o u ll get the
a client list. T alk to the
On the other hand, you
the structure o f central gov
contacts and feedback on the
people. Find out how long
ca n t alw ays ju st assum e
e rn m e n t p la n n in g . T h ey
market you need to make
they've been in business and
things. Its common these
dont know how to deal with
the orders.
how many em ployees they
days to think you can t get a
a free market econom y yet.
G T : W h at a b o u t sp e
have. D on't necessarily be
letter o f credit from Russia.
Its not that they do n t want
c ia liz e d le g a l, f in a n c i a l ,
put o ff by a small size com
W ell, you can if you have
to deal with you, but they
pany. Some o f these people,
the right product and the d e
d o n t alw ays know how or
RN: The first thing to re
especially if the service is
mand is there. I just got in
h av e th e o rg a n iz a tio n a l
member is that you d o n 't
narrowly focused, like trans
o r o th e r serv ices?
have to put these people on
lation. may have only two or
your payroll. The expertise
three employees. Some re
y ou're looking for can be
ally reliable people may have
subcontracted. You can hire
been doing this for years,
a freight-forw arding com
working out o f their homes.
pany, which will do all the
T hey've got great references
paperwork down to and in
and good client lists.
cluding verification and vali
ing to deal with vendors in
handling all (he tariff forms,
your area. Most major m et
the shipping, the bills o f lad
ro politan areas have this
ing. While not a big one, there
built-in infrastructure o f ex
will be a charge for this, o f
p a tria te s from p a rtic u la r
course. T hats why w ere
countries who have exper
back to the business of the
tise in the areas you need.
size of the order. It has to be
A gain, the Foreign C om
big enough to make it worth
m ercial S erv ice or your
The U.S. and Foreign

Commercial Service can be
a big help here too. They
When dealing with new markets

and customers who speak a
I would recommend try
dation o f letters of credit,
incurring these expenses.
MANAGEMENT MATTERS
different language, people tend

to listen more carefully. That same
awareness of customer
concerns should spill over into
the domestic market.
sta te s econom ic develop

m ent agency can help you
contact them .
GT:
W hen
volved in an order for a half
structure to do it. And that
y o u re
m illio n y ards o f denim .
lack can make it really hard
have listso f reliable lawyers,
ev alu atin g all th is in fo rm a
T heres a Ukrainian coop
for you to make money ex
bankers, etc. in given coun
tion, a re th e re any red flags
erativ e o f m an u factu rers
porting to those countries
tries. Say you need an Indian
to look for th a t would indi
looking for this denim, and
right now. In a few years
b a rris te r w ho can speak
cate th a t a p a rtic u la r com
they not only had a certified
itll be different.
Hindi. Theyll be able to pro
pany is a bad ex port risk?
letter of credit, but the money
Its helpful to look at the
on deposit at the Citibank of
evaluation process like a set
New York.
of balance scales. Each o f
vide you with a list.
RN : Some o f the things
A nother good place to
w eve already talked about
look for suppliers o f special
are important. Are there trade
Political co ntinuity is
the factors w e've been talk
ized skills, such as transla
barriers or other factors in
another factor to watch for.
ing about is one weight you
tion, is the Export Yellow
the market that are going to
In Central and Eastern Eu
put on (he scale. A( some
Pages, which is available free
make this too difficult? Po
rope especially, this is diffi
poin(. (he balance is going (o
from (he U.S. Foreign and
litical conditions are also
cult. The person youre deal
tip one way or the other. For
Commercial Service. It has
im portant. For exam ple, I
ing with today may not be
ex a m p le , so m e tim es the
lots of names.
dont think I'd consider try
there in six months - even on
method of payment will be a
44
O E A H
T E C H N O L O G Y
little convoluted, but if w ere
where thinking about export
talking about an order o f sev
ing can help you in the do
eral million dollars, maybe
mestic m arket as well. Its
its worth the extra hassle.
good discipline in this sense:
G T : W h a t a b o u t th e
W hen dealing with a new
language h a rrie r? How im
market, maybe with people
p o rta n t is it to have som e
speaking a d ifferen t lan
one on y o u r pay ro ll th a t
guage, people tend to listen
sp eak s th e language o f th e
b etter, m ore carefu lly to
c o u n try o r c o u n tr ie s to
what that custom er wants.
w hich y o u 're ex p o rtin g ?
That same kind o f attitude
RN: Its useful. Again,

w e 'r e b a c k to e ith e r a
should spill over into the

dom estic market.
m anufacturers rep or a dis
This same effect works
tributor. Its helpful, but its
on other parts o f a business
not absolu tely necessary.
as well. Com panies who ex
The international language
port tend to become much
o f the gear industry is bro
more competitive, even in
ken English. And chances
the dom estic market. When
are, if you get a letter in
exporting, you have to really
Spanish or French or Japa
watch your costs and your
nese, th eres som ebody in
quality control and every
the neighborhood who can
thing else because if a prod
help translate it.
uct is defective, its not as
G T : W h at a b o u t p ro d
easy to retrieve the part and
uct m odifications? Should
fix it when it's sitting in
you p lan to invest in ch a n g
M alaysia. Exporting com pa
ing y o u r p ro d u c t to ap p eal
nies tend to really tighten up
to o v erseas m a rk e ts?
their processes and improve
RN: Yes. You should be
their quality control, produc
prep ared to m ake som e
tivity. and efficiency, and
changes. As a gear manufac
w hile theyre doing it for
turer, for one thing, you have
the overseas m arket, th ey re
to be prepared to m ake your
doing it for the dom estic
products for export to m et
market as well.
ric sp e c ific a tio n s.
G T : O n e fin a l q u e s
On the other hand, dont
tio n : If you h a d 50 w o rd s
redesign the product and
o f a d v ice to a g e a r c o m
then go to the m arket. T h ats
p an y th in k in g o f g ettin g
backw ards. Go to the m ar
in to
ketplace first. Talk to the
w ould th e y be.
e x p o rtin g ,
w hat
QUALITY
GEARS
UP TO AGMA 15. MIL-I-45208A & MIL-STD-45662
FROM A SINGLE GEAR TO LONG RUN PRODUCTION. INCLUDING
PROTOTYPE & EMERGENCY REPAIR/REBUILD SERVICE
SIZE RANGE FROM UNDER 1* to 48 DIAMETER
Reishauer Ground Gears

Most Type Gears Manufactured
Complete to Customer Specifications
METRIC OR AMERICAN STANDARD

SPUR INTERNAL & EXTERNAL
HELICAL INTERNAL & EXTERNAL
WORMS. WORM GEARS
SERRATIONS SHAFTS
SPLINES INTERNAL & EXTERNAL
SPROCKETS CLUSTERS
SEGMENTS SPINDLES
RATCHETS GEAR BOXES
4p
ftS _
Fully implemented SPC, and data

communications capabilities, utilizing
state of the art CMM's and M & M precision
gear checker to 30" diameter to 18* lace.
a i r l a n e C jje t\r y * J J n c .
P.O. BOX 409, PLYMOUTH, Ml 48170
(313) 459-2440
In Mich. 1-800-482-1773 FAX (313) 459-2941
CIRCLE A-1B on READER REPLY CARD
Do You Have Our

Next Cover?
Gear Technology is looking for
good cover art. If you have
a professional photo of
gearing in operation that you think
custom ers. Find out what
RN : First, d o n t fall into
will look good on the next cover
they want. If your customer
the trap o f assum ing that
o f Gear Technology, please send
wants the machine in metric
you c a n t export. Take a
and p ain ted p u rp le, then
c a u tio u s , ju d ic io u s look
that s what you should be pre
around, w ithout any prior
pared togive him. You can have
assum ptions, and y o u ll be
the best product in the world,
surprised w hat you might
but if the customer doesnt
find. T hen, go slow. P ro
want it, you dont have a sale.
ceed with caution. But by
This is one o f the places
all m eans, proceed.
it for review:
Gear Technology Art Dept.

1401 Lunt Ave.
Elk Grove Village, IL 60007
CLASSIFIED
HEAT TR E A T IN G
GEAR HARDENING SPECIAUSTS
with over 50 years experience
Carburizing and Hardening
- Aerospace and M ilitary Approved
Integral Quench Furnaces to 48 X 72 X 36
- Vertical Pit Furnace 18 X 126
- Gleason Press & Hot Oil Quenching
Nitriding
- Large 60 X 72 Furnaces
- State-of-the-art Processing for W hite
layer Control
* Induction Hardening
- NATCO Contour Induction Hardening
- High and Low Volume Coil Induction
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- Automotive Approved SPC
* Metallurgical Consulting & Design Assistance
Contour Induction
Hardening Specialists
Mack
TRU CKS
Spur, helical and bevel gears

Our gear hardening equipment
Includes 4 NATCO submerged
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Write for a free brochure.
COMMERCIAL HEAT TREATING

services include:
carburizing
annealing
normalizing
carbonitriding
gas nitriding
thru-hardening
Metallurgical lab testing available.
American M etal Treating Company
THE CINCINNATI STEEL TREATING COMPANY

(513) 271-3173
FAX (513) 271-3510
1043 East 62nd Street

Cleveland, OH 44103
(216)431-4492
Fax: (216)431-1508
Mack Trucks, Inc.

Dept. 3401
13302 Pennsylvania Avenue
Hagerstown, Maryland 21742-2693
(301)790-5400
THE SYMBOL OF
QUALITY AND SERVICE
SERVICE
ITW GEAR
INSPECTION SYSTEMS
GEAR TOOTH
GRINDING SERVICES
FELLOWS GEAR MEASURING

REMANUFACTURING SPECIALIST
Scrvice - Upgrades - Rebuilds

75 years of design and manufacturing
know-how go into the servicing, re
building. and upgrading of ITW gear
inspection systems. ITW designed
them. ITW built them . ITW knows
how to keep them running.
Factory loaners
Component availability from
your OEM supplier
Latest technology in digital
adjustments
Computerized data evaluation
* Cost effective gear tooth grinding

specialists
* Gear m anufacturers are our only
customers
* Prototype and production quantities
Quick Turnaround
Calibration & Certification to MIL-STD
Preventative Maintenance
* Capacity to 27.5' P.D., 3.5 D. P.
Complete Field Service
* Able to match delivery to your
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requirements
* All service to AGM A standards w ith
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Engineering Support
Leasing & Sales
OVERALL THE BEST IN THE BUSINESS
PRO-GEAR COMPANY, INC.
7300 W Lawrence Ave. Chicago, IL 60656

Phone: 708-867-5353 Fax: 708-867-3838
23 Dick Road Depew, NY 14043

Phone (716)684-3811
Fax(716)684-7717
ITW H eartland
Complete Factory Rebuilding
Profit from our 100 years experience
Profile Engineemg. Inc.

100 River Street
Spnngfield.VT 05156
802-885-9176
Fax 802-885-3745
Rates: Line classified - $37.50 per line. 8 lines per inch. $300 minimum. Classified Display - per inch (3" min.) IX - $ 1 7 0 ,3X-$160,
6X - $150. Type will be set to advertisers layout or Gear Technology will set type al no extra chargc.
Paym ent: Full payment must accompany classified ads. Send check or Visa/Mastercard/American Express number and expiration date
to: Gear Technology. P. O. Box 1426, Elk Grove Village. IL. 60009. Agency Com mission: No agency commission on classifieds.
M aterials Deadline: Ads must be received by the 25th of the month, two months prior to publication. A cceptance: Publisher reserves
the right to accept or reject classified advertisements at his discretion.
46
GEAR
T E C H N O L O G Y
HELP WANTED
MANUFACTURING MANAGER; *65.000 Single He
ItcaJ Gear Botes Metalworking. Turning e spent sc 120
employee*
GEAR ENGINEER: S58.300 Process and Gear Design
MANUFACTURING ENGINEERING MANAGER:
$60,000 Multi-plant responsibility Gear Cutting Large
Diameter Gears
S( PKRYIM IR.SPIRM . BFYEI. GRINDING: S5J.200
Supervise 30
Contact. Ann Hunsucker. Excel Associates. P O Boi
520. Cordova. TN 38018 or call (901 ) 757 9600; or Fa*
(901)754-2896
To advertise in the
classified
section of
Gear Technology
call (708) 437-6604.
SERVICE
Our New, Modernized
Recorder A m plifiers
Improve Your Reliability
F o r Fellows and ITW Illitro n
Now we can replace your old
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than the OEM equipment. Why?
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circuits - the number of com po
nents (and therefore the cost) is
greatly reduced. Our designers
also improved safety by adding
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protection. Order yours today.
PHONE 708 377-2496

FAX 708 377-2546
Put Our List

On Your List
Our list can help you
do the other things you
have on your list. Such
as buy a car...estimate
social security...start the
diet...check out invest
ments...
Our list is the Consumer
Information Catalog. It's free and
lists more than 200 free and lowcost
government booklets on employment, housing, Federal
benefits, and lots of ways you can save money.
So to shorten your list, send for the free Consumer
Information Catalog. It's the thing to do.
Just send us your name and address. Write:
Consumer Information Center
Department LL
Pueblo, Colorado 81009
A puM c awvio* o this publication and me Consigner information Center of Hi* U S General Services Admmtatratton
One O f Americas Best Run Companies

Gives 95% O f Its Money To Charity.
CARE was recently named the best
run. best managed charity in America.
We aren't surprised.
95% o f every dollar we receive
goes to help impoverished people Only
3% goes to run our organization.
Manufactured
Gear & Gage, Inc.
P.O. Box 7155
^ ____________________ Elgin, IL 60121J
No other company could survive

on margins like that. Bui a lot of starv
ing people can.
Were Helping People
Learn To Live Without Us.
1-800-242-GIVE
CARE
C IR C L E A -2 9 on R E A D E R R E P L Y C A R D
1993
"SEEING IS BELIEVING"
Advertise in Gear Technology
and see how many
decision makers you can reach.
CALENDAR
Call (708) 437-6604
today and see for yourself.
M A R C H 11-12
AGM A Technical Education S em i
nar. Ram ada Hotel O 'H are. Rosem ont
(Chicago) IL. "G ear Failure Analysis"
and "Gear Design & A nalysis. Bob
E rric h e llo , se m in a r le ad er.
ATTEND
OUR ANNUAL
KOEPFER
GEAR SCHOOL
Knowledge
is a powerful
tool to have.
C all
AGMA at (703) 684-0211 for more

inform ation.
M A R C H 16-18
ASM International 14th Annual Heat
Treating Conference & Exposition. In
dianapolis. IN. Seminars on heat treat
ing equipment, processes, and perfor
mance. Call (216) 338-5151. x530 for
more information.
A PR IL 19-23
AGMA GEAR TRA IN IN G SCHOOL.
Koepfer America, builder of gear hobbing equipment and tooling,

presents a two day training program for entry-level gear manufacturing
personnel on May 16,17 and 18,1993.
Practical course content includes:
Gear basics
Production estimating
Cutting tool use & support
Fixturing techniques
Inspection & interpretation
of charts
Problem solving session
Equipment demonstration
IIT Research Institute, Chicago, IL.

Covering basics o f bobbers, shapers,
and inspection. Call AGMA, (703)6840211 for more inform ation.
A P R IL 20-22
Q uality Expo International. O 'H are
Expo Center. Chicago. IL. Covering
quality assurance/reliability equipment,
systems, and services. For registration
information, call (800) 32 3 -5 155 or fax
(708) 260-0396. Outside the U.S. or
For additional
information
telephone...
Canada, call (708) 260-9700.

A P R IL 27-29
SME A dvanced G ear Processing &
M anufacturing Clinic. Dallas M arriott
A rlington, A rlington (D allas), TX.
OCIII KJIUCT UIIVC OUUIII

Telephone 708-931-4121 Fax/08-931-4192
Jos. Koepfer & Sohne GmbH Furtwangen, West Gennany
T o p ic s in clu d e h o b b in g , sk iv in g ,
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Or FAX (313) 271-2861.
Heat Treating Solutions

Let Us Provide One For You...
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high quality. Here, reaction shafts are
hardened at the rate of 300 parts per
hour. Simple yet effective.
U ltra-C ase gear hardening-your

answer to carburizing. Ultra-Case is
a high speed method for contour gear
hardening. It provides the user with
the ability to surface harden gears at
production line speeds while at the
same time it solves dimensional
distortion problems.
ScanP ak. A versatile vertical

scanner that allows the user to
harden shaft-like parts from cam
shafts to hydraulic pistons, ScanPak
is available in nine different config
urations, in power ratings up to
800 KW, in frequencies to 50 KHz.
Whether you need single spindle,
dual spindle, or twin drive, there is
a ScanPak exactly suited for you.
ScanPak comes equipped with
microprocessor-based machine
control, integral heat station, and
with spindle sizes up to 60*.
Let Ajax help make your next heat treat project a success. Write to: Ajax Magnethermic
Corp., 1745 Overland Avenue, Warren, Ohio 44482. Call toll-free 1-800-547-1527,
Fax (216) 372-8644 or in Canada call (416) 683-4980.
T h e W a y T h e W o r l d In d u c t s Its B u s in e s s
WARREN. OHIO USA / TORONTO. CANAOA / UNITED KINGDOM I CARACAS, VENEZUELA / SAO PAULO. BRAZIL
SEOUL, KOREA I MELBOURNE. AUSTRALIA / BILBAO. SPAIN / TOKYO. JAPAN / FRASER. MICHIGAN
THE
INDUCTION
EDGE
TDCCO PROFILE HARDENING (TPH) eliminates three of
a gear user's worst problems:
tooth breakage
pitting
spalling
Gears processed by the TPH process exhibit in
creased hardness and strength at the pitch line with an
optimum strength gradient at the root fillet. These metallur
gical properties are achieved without excessive tip
temperature and without tooth form brittleness.
Don't confuse the TOCCO TPH process with con
ventional dual frequency induction heating. The TPH
process merges three distinct induction heating tech
niques: sequentially-programmed, audio low frequency
preheating, incremental induction hardening and
high intensity radio frequency final hardening. The
result is good austenitic/martensitic transformation
and beneficial residual compressive stress at the root
with elevated hardness and strength/depth at the
pitch line
The TPH process accommodates a broad range
of metals, induding medium carbon steel, cast iron
and powder metals. You're not locked into expensive
alloy steels. The process is economical for batches of
one or 1,000, and is used today by top automobile
and gear manufacturers.
Gear Profile Hardening is
another example of the
edge" TOCCO gives
you in induction heating.
Our metallurgists will send
you a fresh report on TPH
technology. All you need
do is ask

- *
30100 Stephenson Hwy

Madison Heights. Ml 48071
TEL: (313) 399 8601
FAX (313)399 8603

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GEAR

SPECIAL FOCUS ON HEAT TREATING

A All maintenance points accessible

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CIRCLE A-4 on REAOER REPLY CARD

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Better technical support and service

CIRCLE A-10 on READER REPLY CARD

says the phil

make all the difference.

osopher. W hat he meant was that on the scale

Likewise, while not every reader will have

o f the universe, it's not ju st the galaxies, the

occasion to use the technology discussed in our

planets, the m ountain ranges, or the m ajor

Gear Fundam entals feature. Introduction to

rivers that are im portant. So are the subatom ic

Worm G earing," as the author points out, care

particles and the genes. I t's the little things

ful attention to detail can make this old fash

that make all the difference.