APRIL 2011

Milling
Tools for
Bevel Gears
Better Bevel Gear
Production
Clamping Large
Turned Parts

Site Safety
Tooth Tips
HOT SEAT
AGMA UPDATE

Company Profile:
Banyan Global Technologies, LLC

Q&A:
Allan Arch
Southern Gear &
Machine, Inc.

Ahead
Your Future, Our Future
Predictive Process Control
The NILES ZE Series has NEW features:
High feed-rate grinding, Module 25
(1 NDP), High-speed measurement
for full contact grinding.
See What’s
KAPP Technologies
2870 Wilderness Place Boulder, CO 80301
Phone: (303) 447-1130 Fax: (303) 447-1131
kapp-coburg.de | niles.de | kapp-usa.com
kapp-asia.com | kapptec.com
info@kapp-usa.com
48
Milling Tools for
Bevel Gears
Features
By Guenter Wermeister
Close collaboration between
industry partners creates efficient,
productive, and high-quality Company Profile:
solutions for gear milling, according Banyan Global
to Sandvik Coromant. Technologies, LLC

30
By Russ Willcutt

With decades of combined

experience in the cutting tools and
abrasives used in manufacturing
gears, this company is taking
a hybrid approach to serving
customers.

Better Bevel Gear

Production

32
By Michael Hayes
Gleason’s newly designed
Phoenix 280C bevel gear cutting
machine is faster and easier to
use than ever before, providing
dependability and boosting
productivity.

Clamping Large
Turned Parts
By Steve Hartung

42
Many industries, such as renewable
energy, require large parts, so
machine shops should review their
workholding equipment to make
sure they’re up to the task.

APRIL 2011 3
 Resources
MACHINES Departments
61 Industry News
MARKETPLACE

65
Trends, data, and developments to keep you aware of what’s
happening with your colleagues in the gear-manufacturing
industry around the country and world.
8
Site Safety
ADVERTISER
INDEX
Terry McDonald
Improperly handling cutting tools isn’t the only way they can cause injury, as
24
67
manufacturing flaws or environmental influences can cause breakage.

Tooth Tips
APRIL 2011 | VOLUME 9 / NO. 97

Gear Solutions (ISSN 1933 - 7507) is

William Crosher
Material removal doesn’t always involve blades, as there is the Electric Discharge
Method, Electro Chemical Machining, and other approaches.
26
published monthly by Media Solutions,

28
Inc., 266D Yeager Parkway Pelham,
AL 35124. Phone (205) 380-1573 Fax
Hot Jack
SeatTitus
(205) 380-1580 International subscrip-
tion rates: $72.00 per year. Periodicals In response to an increased interest in high-pressure gas quenching (HPGQ), the
Postage Paid at Pelham AL and at addi- author addresses the issue in this month’s installment.
tional mailing offices. Printed in the USA.
POSTMASTER: Send address changes
Product Showcase
53
to Gear Solutions magazine, P.O. Box
1210 Pelham AL 35124. Publications mail
agreement No. 41395015 return undeliv- News of products, equipment, and resources from across the
erable Canadian addresses to P.O. Box manufacturing spectrum that will help propel your
503 RPO West Beaver Creek Richmond company toward success.
Hill, ON L4B4R6. Copyright®© 2006 by
Media Solutions, Inc. All rights reserved.

No part of this publication may be repro-

duced or transmitted in any form or by any
means, electronic or mechanical, includ-
ing photocopy, recording, or any informa-
tion storage-and-retrieval system without
Southern Gear & Machine, Inc
Q&A
Allan Arch, President
68
permission in writing from the publisher.
The views expressed by those not on the
staff on Gear Solutions magazine, or who American
are not specifically employed by Media
Solutions, Inc., are purely their own. All
Gear Manufacturers
"Industry News" material has either been Association
submitted by the subject company or
pulled directly from their corporate web
site, which is assumed to be cleared for In this section the premier supporter of gear manufacturing in the United States
release. Comments and submissions
are welcome, and can be submitted to
and beyond shares news of the organization’s activities, upcoming educational and
editor@gearsolutions.com. training opportunities, technical meetings and seminars, standards development,
and the actions of AGMA councils and committees.

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

Cover: Sandvik Coromant

APRIL 2011 5
 Letter
From THE EDITOR David C. Cooper
Publisher
When Allan Arch, president of Southern Gear & Machine, addresses undergradu-
ate engineering students at Florida International University in Miami, he takes
Chad Morrison
Associate Publisher
along a selection of gears and some of the tools he used to make them. As the
gears are passed from hand to hand he explains what they are, what they’re
made of, why they’re shaped the way they are, and how they were manufactured. EDITORIAL
I’d be willing to bet the result is a class full of students who have been awakened Russ Willcutt
to a world they didn’t even know existed, and one they might decide to pursue. Editor
At a time when there’s a severe shortage of students choosing to enter manufac-
turing, I can’t imagine a better grass-roots approach to tackling this issue than
one man, standing before a class of curious students, describing one of many Sales
paths they might choose to take. Maybe you have similar skills and experiences Brad Whisenant
to share. I’m sure a local university or community college would be interested in National Sales Manager
hearing from you. You can learn more about Allan’s work in this month’s Q&A.
Our feature lineup is equally inspiring, starting with “Milling Tools for Bevel Circulation
Gears” by Guenter Wermeister of Sandvik Coromant, in which he describes how Teresa Cooper
collaboration between industry partners leads to quality solutions for gear mill- Manager
ing. Continuing the theme of bevel gearing, Michael Hayes discusses Gleason’s
newly designed Phoenix 280C bevel gear cutting machine in “Better Bevel Kassie Hughey
Gear Production,” pointing to advances that have resulted in a machine that’s Coordinator
faster, more versatile, and easier to use than ever before. Steve Hartung of
SCHUNK, the specialists in toolholding, workholding, and automation, has writ- Jamie Willett
ten “Clamping Large Turned Parts,” encouraging machine shops to review their Assistant
workholding equipment to make sure they’re up to the task. As he concludes his
tenure, Dave Ballard relates his experience as the AGMA’s first two-year chairman
in the association’s special section, which also welcomes companies that have ART
joined recently and new members of the Board of Directors. It’s an honor for us Jeremy Allen
to have the opportunity to share this wealth of expertise with you. Art Director
The same holds true for our columnists, with Jack Titus exploring the subject
of high-pressure gas quenching (HPGQ) in this month’s installment of his “Hot
Michele Hall
Graphic Designer
Seat” column. Bill Crosher writes about material removal techniques including
the Electric Discharge Method and Electro Chemical Machining in “Tooth Tips,”
and in “Site Safety” Terry McDonald advises cutting tool users to remember that Contributing writers
injuries can result from tool failure, not just mishandling sharp edges. Banyan William P. Crosher
Steve Hartung
Global Technologies is this month’s company profile, and I’d like to thank Darryl Michael Hayes
Witte for taking the time to share their story with us. Terry McDonald
GEAR EXPO 2011 is coming up this fall, as you know, and it will be held Jack Titus
Guenter
VerticalWermeister
Logo
November 1-3 at the Duke Energy Convention Center in Cincinnati, Ohio. We
will be publishing two issues of the magazine supporting the show that we’ll be
handing out there, so I would encourage you to contact me at the e-mail address
listed below if you’re interested in contributing an article about your cutting-edge
technologies, new equipment designs, materials research, and/or manufacturing
processes. I look forward to hearing from you!

Published by Media Solutions, Inc.

P. O. Box 1987 • Pelham, AL 35124
(800) 366-2185 • (205) 380-1580 fax

Russ Willcutt, editor David C. Cooper

Gear Solutions magazine President
editor@gearsolutions.com
(800) 366-2185 Chad Morri son
Vice PresidenT

Teresa Cooper
Operations

6 gearsolutions.com
 INDUSTRY
NEWS New Products,
Trends, Services,
and Developments

Hexagon Metrology Opens New Factory and R&D Center

Hexagon Metrology, Inc., announces the completion and opening of its newest facility Hexagon Metrology is part of the
located in Oceanside, California. The state of the art factory and research and develop- Hexagon AB Group and includes lead-
ment center will serve as the North American manufacturing headquarters for the ROMER® ing metrology brands such as Brown
brand of portable coordinate measuring machines. The new 14,000 square-foot facility & Sharpe, CogniTens, DEA, Leica
was designed specifically for the production of portable coordinate measuring machines Geosystems (Metrology Division), Leitz,
such as the newly released Absolute portable articulating arm series. The layout and m&h, PC-DMIS, ROMER, Sheffield, and
design of the new building integrates the latest in JIT and lean manufacturing concepts TESA. Hexagon Metrology brands rep-
which enables efficient, cost effective, and higher volume production of the high precision resent an unrivaled global installed
devices. base of millions of Coordinate
The new Hexagon Metrology plant also includes an expanded R&D facility to drive innova- Measuring Machines (CMMs), porta-
tion in the portable metrology market. All manufacturing and R&D functions in Hexagon’s ble measuring systems and handheld
Carlsbad, California, facility will transition to the new Oceanside location starting on March instruments, and tens of thousands of
1, 2011, with full customer services and operations projected to commence on the fol- metrology software licenses. Hexagon
lowing Monday. Metrology empowers its customers to

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

8 gearsolutions.com
 fully control manufacturing processes that
rely on dimensional precision, ensuring that
products manufactured precisely conform
to the original product design. The com-
pany offering of machines, systems, and
software is complemented by a wide range
of product support, aftermarket, and value-
added services. For more information call
the Hexagon Metrology Seagate Corporate
Center at (760) 994-1401 or visit [www.
hexagonmetrology.us].

Schafer Gear Announces Joint

Venture with Somaschini
Schafer Gear Works, Inc., with headquarters
in South Bend, Indiana, and Somaschini
S.p.A. of Italy announce a joint venture to
produce gears for engines for the heavy-
duty truck market in North America. A new
manufacturing facility will be located in
South Bend under the name of South Bend
Gear LLC. The plant will utilize the process
technology developed by Somaschini S.p.A.
in Italy with Schafer Gear managing the
operations. As part of the joint venture, a
new 50,000-square-foot plant is being built
on the Schafer Gear campus. Production
is scheduled to begin in late 2011 at 50
percent capacity and will reach 100 percent
production capacity by the end of 2012. The
new plan will employ 12 people in phase
one and an additional 13 people, for a total
of 25 people when fully operational. The
total joint venture investment is $18 million,
including the new manufacturing facility.
“We are extremely excited about the oppor-
tunity this joint venture brings to Schafer
and to South Bend,” says Bipin Doshi, presi-
dent of Schafer Gear. “Somaschini’s long
history of quality gear production and its
proven technology complements our world-
wide reputation for precision cut gears and
precisely machined components.”
Somaschini has been supplying gears for
the heavy-duty truck market to a number
of customers including the Daimler Group
since 1992. In 2008 the Italian manu-
facturer began supplying engine gears to
Detroit Diesel Corporation (DDC), a leading
manufacturer of on-highway diesel engines
for the commercial truck market. DDC is
part of the Daimler group that also owns
Freightliner and Western Star truck compa-
nies. DDC has developed a series of highly
energy-efficient engines that also meet the

10 gearsolutions.com
latest environmental regulations. South to Mike Casto at casto@americanbroach. com or (734) 961-0300. Go online to
Bend Gear will produce gears for Detroit com. All broach tool engineering, tool [www.americanbroach.com].
Diesel’s DD13, DD15, and DD16 series engineering questions, or requests for
engines. Somaschini will continue to meet broach tool quotes go to David Terpstra at Mazak Appoints New Service
the increased demands for the European dt@americanbroach.com. Effective March Manager
and the Japanese markets. 7, 2011, Carl Staton will no longer be an Mazak Corporation has appointed Steve
Somaschini S.p.A. was established in employee of American Broach, so please Mackay to the position of service man-
1922 in Trescore Belneario (Bergamo) transfer any communication or needs to ager at Mazak Corporation Canada in
Italy, east of Milan. They are a diversified Neal Henrique at neal@americanbroach. Cambridge, Ontario. Mackay has an exten-
supplier of gears to a variety of markets
in Europe including automotive, passen-
ger and heavy-duty trucks, motorbikes,
marine, textile machines, machine tools,
robotics, railway, and renewable energy. In
2007 Somaschini established Automotive
S.r.l. in a separate modern new facility in
Entratico to bring all high-volume automo-
tive production into a dedicated plant.
Established in 1934, Schafer Gear
Works has been under its present owner-
ship since 1988. The gear manufacturer
is a diversified supplier to a variety of
markets in North America including lei-
sure vehicles, material handling, mining,
power transmission, construction, loco-
motive, aircraft, and medical, as well as
automotive and heavy-duty truck markets.
Learn more at [www.schafergear.com] or
[www.somaschini.com].

Promotion at American Broach

American Broach announces the promo-
tion of Neal Henrique to broach depart-
ment floor supervisor, responsible for all
broach cutting tool processes and manu-
facturing schedules. He has been making
broach tools since 1973 and is a dedicat-
ed craftsman with hands-on knowledge of
broaching that only comes with 38 years
of experience. He is committed to serving
the company’s customers and the use of
quality systems to continue improving its
product quality and delivery. Henrique’s
goal is to not only to meet customers
expectations, but to exceed them. He will
be responsible for orders after they are
released from engineering, including all
delivery schedules, quality, and corrective
action plans. He will be communicating
with staff, customers, and the sales team
to assure customer satisfaction and effi-
ciency in manufacturing.
When contacting American Broach,
please keep the following in mind. All sales
or customer service-related questions go

APRIL 2011 11
sive background in the machine tool Committed to being a partner to cus- on Demand” manufacturing concept uses
industry, with responsibilities at previous tomers with innovative technology, its the latest in machine tool technologies
positions encompassing service, instal- world-class facility in Florence, Kentucky, as part of its lean strategy. Continuous
lation, and project management. “Steve recently initiated a $9 million manufactur- training and development of the work-
brings over 20 years of experience and ing expansion. The facility’s “Production force has created a “lean” culture, which
service expertise that is invaluable,” says
Ray Buxton, general manager at Mazak
Canada and Technology Center. “His
considerable knowledge of the industry
and experience in machine installation
and repair make him a key asset to our
team.”
Mackay’s responsibilities include over-
seeing machine installations, all war-
ranty and non-warranty machine repair,
and managing Mazak Canada service
personnel and contractors. “Mazak is a
true leader in our industry, and I’m very
proud to be part of the team,” he says.
“Everyone wants to be the best at what
they do, and working with the best is a
good way to make that happen.”
Mazak Corporation is a leader in the
design and manufacture of productiv-
ity-improving machine tool solutions.

12 gearsolutions.com
has created opportunities for continuing ETA, e-Xstream, BSim, Faurecia, FIAT, to [www.lmsintl.com/events/lmsconfer-
growth in America. Mazak maintains eight Fraunhofer Lbf, GM Powertrain, IFE Doors, ences/europe].
technology centers across North America IFP Energies nouvelles, LG-Chem CPI, John
to provide local hands-on applications, Deere India, Magna Powertrain, Magneti Showroom on Wheels by
service, and sales support to its custom- Marelli, Piaggio, PSA Peugeot Citroën, DE-STA-CO
ers. For more information visit [www. Saab Auto, Tata Motors, Voith Turbo, DE-STA-CO announces the debut of its
mazakusa.com]. Wärtsilä, WDL, and ZF Lenksysteme. “Showroom on Wheels” traveling, exhibit-
For more information, registration, and ing vehicle. The Showroom on Wheels will
Keynote Speakers at LMS practical details about the conference go be visiting North American industry trade
European Vehicle Conference
Announced
LMS International, a leading partner in
testing and mechatronic simulation, is
pleased to announce the keynote speak-
ers at the 2011 LMS European Vehicle
Conference to be held at the Kempinski
Hotel Airport in Munich, Germany, May
11-12, 2011. The conference will host
Prof. Dr. Ludger Dragon, head of vehi-
cle dynamics simulation at Daimler; Eric
Landel, expert leader numerical model-
ing & simulation at Renault; and Prof.
Dr.-Ing Holger Hanselka, director at
the Fraunhofer Institute for Structural
Durability and System Reliability, as key-
note speakers.
“We are greatly pleased that Prof. Dr.
Ludger Dragon, Mr. Eric Landel and Prof.
Dr.-Ing Holger Hanselka will present their
visionary approach to the eco- and brand
value engineering challenges in the auto-
motive sector,” according to Dr. Urbain
Vandeurzen, LMS chairman and CEO. “Our
aim is to provide a meeting place for the
automotive and ground vehicle commu-
nity to exchange ideas and find ways to
respond to the current challenges in the
industry.”
The two-day conference is the ideal
venue to discover real-life business appli-
cations and the latest technological evo-
lutions presented by leading industry
experts, and to experience simulation
and testing solutions and products from
LMS and its partners. The conference will
bring together engineering executives,
senior managers, and technical experts
who will share strategies that illustrate
how simulation supported by continuous
progress in physical testing has helped
them optimize their products and product
development processes.
The following companies have already
confirmed their participation: AUDI, Behr,
BMW, CNH, Continental, Daimler, Denso,

APRIL 2011 13
shows and customer sites beginning in
March, with initial stops planned for the
Southeast. It debuted at Automate 2011,
which took place at the McCormick Place
in Chicago.
The vehicle is 24 feet long, with an
interior large enough to accommodate the
complete DE-STA-CO product line mounted
on multiple display boards. Even large-
scale products are displayed, including
valve-actuated pneumatics, a pick-and-
place robot, and a coin stamping machine
featuring DE-STA-CO’s CAMCO® products.
A large video monitor swings out so that it
can be viewed through the open side door,
allowing video programs to be displayed in
conjunction with product demonstrations
and training sessions.
“The Showroom on Wheels enables us
to take the full DE-STA-CO product line
on the road to give customers a close-
up look at all that we offer,” says John
Bubnikovich, director of global marketing
and segment strategy. “We’re looking
forward to driving it from coast to coast
to let people see and feel the outstand-
ing quality we build into every one of our
products.”
DE-STA-CO is a global automation and
workholding company, providing produc-
tivity solutions for the industry since
1915. Quality, innovation, and service
have made the company a leader in the
design and manufacture of cost reducing,
flexible automation solutions for industri-
al customers around the world. For more
information go online to [www.destaco.
com].
14 gearsolutions.com
New Brochure from Advanced Metallurgical Reference Booklet
Machine & Engineering for Vacuum Furnace Users
Advanced Machine & Engineering Co. In a joint effort, Solar Atmospheres and
(AME) announces the new “Workholding Solar Manufacturing have produced an
Solutions” brochure. The 12-page overview updated booklet titled “Critical Melting
brochure describes modular components, Points and Reference Data for Vacuum
Self-Aligning Fixture Elements (S.A.F.E.), Heat Treating.” This handy reference
grids, force cartridges, tombstones, locat- manual allows the vacuum furnace user
ing systems, and high-density workholding to quickly find and understand essential
systems. AME’s wide variety of workhold-
ing solutions are tailored to your needs;
dedicated or modular, manual or hydrau-
lic, machining or inspection fixtures, incre-
mental or turnkey services. In addition to
an extensive inventory of components,
AME offers complete design and build as
well as technical consulting services.
Advanced Machine & Engineering Co.
is a manufacturer serving the machine
tool industry with precision components
and accessories including spindle inter-
face components, workholding devices
and, through its sister company, Hennig,
machine enclosures, chip removal, and
filtration systems. The fluid power and
safety markets are served with cylinder
rod locks and safety catcher devices, and
the production saw market with AmSaw
carbide saw machines and Speedcut blade
products. AME has manufacturing part-
ners and customers around the world and
across the United States. Hennig, Inc., data on various metals and alloys to be
designs and produces custom machine processed in a vacuum environment.
protection and chip/coolant management According to Roger Jones, president of
products for state of the art machine tools. Solar Atmospheres, “multiple tables are
To learn more visit [www.hennigworldwide. included highlighting melting points of ele-
com]. Contact AME at (815) 316-5277, ments and many alloys of stainless steel,
info@ame.com, or [www.ame.com]. aluminum, copper, magnesium, nickel,
and titanium, among others.” developed by C&B engineers, also allows our very company. These special grinding
“Other data incorporated relates to 100 percent gage feedback on every compo- cells are designed to change over from
eutectic, emissivity, and vapor pressure nent ground. Size control is tightened result- part to part in as little as three minutes.
concerns when operating at certain tem- ing in higher statistical capability. Considering that production double disc
peratures and/or under vacuum,” says Jim “Flexibility is a very strong requirement grinders have been historically dedicated
Nagy, president of Solar Manufacturing. for customers today,” says Chris Cox, vice machines, it is quite an about face. The
“Various conversion tables relating to president of sales. “In parallel, it is now most important aspect of this project
pressure and vacuum have been pro- one of the main selling features of C&B is to convey on a global scale, that the
vided.” Machinery’s grinding systems, as well as American Machine Tool Industry is still
Solar Atmospheres is one of the largest
privately owned vacuum heat treating and
brazing companies in the United States.
Solar Manufacturing is a leader in the
manufacturing of all types of standard
and specialized vacuum heat treating and
brazing furnaces. To request a copy of
this booklet, which is being made avail-
able to all vacuum furnace users at no
charge, visit [www.solaratmopheres.com]
or [www.solarmanufacturing.com].

C&B Machinery Lands Order

from Allison Transmission
C&B Machinery has been awarded an order
by Allison Transmission to build a “flex-
ible” double disc grinding cell for its facil-
ity in Chennai, India: Allison Transmission
India Private Limited. The grinding cell is
designed to grind the faces of transmission
pinion gears for Allison’s 1000 and 2000
series transmissions. Double disc grind-
ers remove equal material from both faces
simultaneously. This particular machine
will be arranged to grind four various pinion
configurations with the capability to grind
11 more already being produced at the
plant on grinders previously provided by
C&B.
The machine employs a “rotary plunge”
grinding cycle, which means the pinions are
introduced to the grinding wheels via a rota-
ry carrier one at a time while the grinding
wheels plunge grind simultaneously through
axis interpolation. There are several advan-
tages for grinding in this manner, with the
most important one being that the grinding
wheels are adjusted perfectly parallel and
concentric to each other. Conventional dou-
ble disc grinding most often requires com-
pound head settings. Keeping the wheels
parallel results in more uniform wheel wear
and reduced frequency of dress cycles,
ultimately saving in abrasive expenditures.
Cost per piece is reduced and return on
investment is quicker. This grinding cycle,

APRIL 2011 15
 alive and well. We have the talent
base and the ingenuity to compete
globally and produce and support
some of the highest quality and
most flexible grinding systems avail-
able anywhere in the world.” Contact
Cox at (734) 462-0600, ccox@cbma-
chinery.com, or [www.cbmachinery.
com].

Engis Plans Expansion of

World Headquarters
Engis Corporation announces expan-
sion plans that will nearly double
the size of its world headquarters in
Wheeling, Illinois, a Chicago suburb.
The company will expand its state
of the art manufacturing and ware-
house facilities and create space for
the new Engis Technology Center.
The 54,000 square-foot, multimil-
lion-dollar expansion will bring total
space to 121,500 square-feet and
enable the company to consolidate
all engineering, process develop-
ment labs, manufacturing, ware-

16 gearsolutions.com
housing, and administrative offices into
a single facility. In conjunction with this
project Engis will add new manufacturing,
process development and testing and
measurement equipment. Construction
will start in April and be completed by fall
of 2011.
“This expansion demonstrates our long-
term commitment to customers as a
leading-edge provider of superabrasive
solutions,” says Stephen Griffin, presi-
dent. “For example, new automated manu-
facturing equipment will enable us to
increase our ability to support global mar-
kets, while the Engis Technology Center
will enhance our capability to develop
turnkey manufacturing solutions. It also
demonstrates our commitment to keep
and generate future jobs in Wheeling and
in the United States.”
Engis Corporation is a leading worldwide
provider of superabrasive finishing sys-
tems and HYPREZ high precision micron
diamond and CBN powders. Engis solu-
tions include grinding, honing, lapping,
and polishing products, as well as fully
configured, custom-developed manufac-
turing systems. Industries served include
oil and gas, electronics, semi-conductor,
medical devices, aerospace, defense,
ceramics, mold/tool/die, automotive,
mechanical valves/seals, foundries, and
more. To learn more call (800) 993-6447,
e-mail info@engis.com, or go to [www.
engis.com].

New High-Speed Laser Controls

from FANUC
FANUC Factor y Automation America
(FANUC FA America) introduces the Series
30i/31i-L MODEL B high-speed laser con-
trols capable of supporting advanced
levels of high speed laser processing.
They have the capacity to deliver seam-
less choreography between axes motion

APRIL 2011 17
and power modulation, even in cases of
extremely high speeds when process-
ing thin gage materials. Internal laser
power stabilizing characteristics deliver
edge conditions on thicker materials that
redefine the norm of RZ and RA (mea-
sured length of surface roughness). Truly
unique in laser processing, smooth edge
18 gearsolutions.com
cross sections with superior edge fin-
ishes quantify smoothness rather than
surface roughness.
Reliable and versatile, the sophistica-
tion of the new FANUC laser controls
lends innovative excellence and impres-
sive processing characteristics to the
base units. The new Series 30i/31i-
L MODEL B CNCs provide exceptional
performance, superior technology, and
impressive gains in processing speeds
and power modulation, which translates
into shorter cycle times and increased
edge quality. Relative to other CNCs in
its class this control has update rates
of 125 microseconds, arguably 40 times
faster than the rate at which a single
neuron can fire within the human brain.
These technological features translate
to superior cut quality and accuracy;
which translates into premium quality
parts and a realized competitive distinc-
tion.
FANUC Corporation is the most diversi-
fied manufacturer of factory automation,
robots, and robomachines in the world.
Since its inception in 1956 it has con-
tributed to the automation of machine
tools as a pioneer in the development of
computer numerical control equipment.
Go online to [www.fanucfa.com].
Latest Powder Metallurgy
Trends at PowderMet2011
PowderMet2011, an annual confer-
ence sponsored by the Metal Powder
Industries Federation (MPIF) and APMI
International, will highlight the latest
developments and trends in metal pow-
ders, as well as powder metallurgy (PM)
processes, products, and applications.
This International Conference on Powder
Metallurgy & Particulate Materials will
be held May 18-21 at the San Francisco
Marriott Marquis Hotel in San Francisco,
California. The 2011 International
Conference on Tungsten, Refractory &
Hardmaterials VIII will run concurrently
with PowderMet2011 at the same loca-
tion. The conference technical program
will feature over 225 technical presenta-
tions by authors from over 30 countries,
and a trade exhibition will showcase
leading suppliers of metal powders and
particulate materials, processing equip-
ment, and PM products.
The conference opening general ses-
sion will include a keynote presentation
by Afternburner, Inc., featuring fighter
pilots who impart their critically honed
team skills to the business world. It will
also include an overview of the annu-
continued on page 59 >
 American
Gear Manufacturers
Association

Looking Back: Two Years at the AGMA

Having been the first two-year term chairman for AGMA, I can say that it has been
a tremendous experience. It has allowed me to grow personally, and to guide our
association in a direction that I hope will benefit the members and the industries
I can assure you they serve for many years to come. AGMA is involved in areas that require it to keep
stepping forward in meeting the needs of its members. These needs go beyond
that I will continue the domestic committees and now take AGMA into a global outreach to serve both
domestic and international members.
to work with the During the past two years AGMA has navigated successfully through a most se-
vere economic downturn. Nonetheless, as good stewards of the investments of our
members and the member companies, we made some great steps ahead. These and other endeav-
ors will ensure that AGMA continues to bring value to its members and the industry
association to ensure into the future.
Several years ago our Board of Directors decided to sell the office condo—that
the success of the AGMA had outgrown and had owned since 1984—and moved to leased office
space. When that lease expired, rather than renewing the Board chose to pur-
industry and its chase a new office location, which opened in December 2010.
Responding to the market and input from our members, we formed a new techni-
member companies. cal committee to tackle energy efficiency of products from our industry. This com-
mittee is well underway with the design of a new online software tool that will help
users optimize efficiency in the design of geared power transmission systems.
AGMA will continue to develop educational programs that focus on the training
needs of the next generation of engineers and machine operators. We are also
committed to continue providing economic forecasting information pertaining to
the growth of the various sectors within the U.S. economy as they relate to our in-
dustry. But there’s more to the story than just the United States.
Understanding that the world gets smaller every day, the association is planning
an economic summit in Budapest, Hungary, that will focus on the industry from a
global perspective. This will allow the major global gear reducer manufacturers,
component suppliers, and some of the primary machine suppliers to meet and dis-
cuss mutual concerns and gather additional information on the evolving global gear
market.
I have had the pleasure of visiting many customers during my tenure as chair-
man, and with every visit I was impressed with meeting the machine operators and
staffs. The machine operators and shop personnel clearly display a dedication and
quality focus that is very important for competing in this industry. I would not hesitate
to contact any of these shops if and when I need to purchase gears.
At the upcoming AGMA Annual Meeting in San Antonio, Texas, I will wrap up my
tenure as the first two-year chairman. It is unfortunate that I could not visit all of the
AGMA member companies and shops, but as I continue in the industry I can assure
you that I will continue to work with the members and the association to ensure
David Ballard the success of the industry and its member companies. At the meeting I will “pass
AGMA Chairman of the Board the gavel” to the incoming chairman, Matt Mondek. I wish Matt much success and
Corporate Manager, SEW-Eurodrive enjoyment during his two years as the chairman of AGMA.
chairman@agma.org
www.agma.org
JANUARY 2010 19
AGMA Welcomes Its Newest Members
AGMA is happy to report that the association continues to grow and now has more than 425 companies in its membership representing the industry in more than 30 countries. In the
past six months, more than 20 companies have joined AGMA. To find out more about these companies, visit their Web sites. To learn about AGMA and how membership can benefit
your company, visit www.agma.org or e-mail membership@agma.org.

Bucyrus International, Inc.
www.bucyrus.com
Bucyrus International is a world leader in
the design and manufacture of high pro-
ductivity mining equipment for surface and
underground mining. Bucyrus surface
equipment is used for mining coal, copper,
iron ore, oil sands, and other minerals, and
underground equipment is used primar-
ily for mining coal. In addition to machine
manufacturing, Bucyrus manufactures
high-quality OEM parts and provides world-
class support services for its equipment.
Bucyrus International is headquartered in
South Milwaukee, Wisconsin.
Cameron Compression Systems
www.c-a-m.com
Cameron is a leading provider of flow equip-
ment products, systems, and services to
worldwide oil, gas, and process industries.
Leveraging its global manufacturing, engi-
neering, and sales and service network,
Cameron works with drilling contractors,
oil and gas producers, pipeline operators,
refiners, and other process owners to con-
trol, direct, adjust, process, measure, and
compress pressures and flows.
Chemineer, Inc.
www.chemineer.com
Chemineer is a supplier of mixing solutions
and products to customers worldwide.
Since 1952 the Chemineer name has
come to be well known in the chemical
and petrochemical, pharmaceutical, bio-
technology, polymers, and food and grain
processing industries.
Columbia Helicopters, Inc.
www.colheli.com
Founded in 1957, Columbia Helicopters
has expanded to include a worldwide fleet
of over 30 aircraft and approximately 800
employees. Since 1969 it has become
the world leader in helilogging, annually
yarding more timber than any other com-
pany.
Evonik Rohmax
www.evonik.com
Evonik Rohmax supplies chemical addi-
tives designed for use in automotive and
industrial lubricants, fuels, and refinery
processing. Evonik Rohmax is part of
Evonik Industries AG, a global market
leader in specialty chemicals.
Grupo Meusnier, S.A. de C.V.
www.meusnier.com.mx
Meusnier is a leader in the manufacture
and repair of mechanical components
for power transmission equipment. Their
diversity of products and services range
from individual components to complete
power transmission systems.
Luren Precision Chicago Co., Ltd.
www.luren.com.tw
Founded in 1994, Luren Precision started
the production of gear cutting tools at
Hsin-Chu Science-Based Industrial Park
in Taiwan. The key members who came
from the Industrial Technology Research
Institute (ITRI) had hands-on experience
on high technology and high precision ma-
chinery to produce aircraft gears and com-
ponents. Luren Precision has three main
departments, which focus on gear cutting
tools, spin pumps and machinery. In addi-
tion, Luren has established a technology
development team which integrates Uni-
versities and ITRI to assist Luren in provid-
ing manufacturing solutions for various

Calendar of Events
Whether you’re looking for technical education, networking opportunities, or a way for your voice to be heard in the standards process, the AGMA has
something to offer you. If you would like more information on any of the following events visit www.agma.org or send e-mail to events@agma.org.

New Orleans, LA
San Antonio, TX

2011 AGMA/ABMA Flexible Couplings

Annual Meeting Committee Meeting

14-16 27-28,
April
4-8 19-20
Gear Accuracy
MDA-Hannover
Messe 2011 Committee Meeting

Chicago, IL

Hannover,
Germany
AGMA Pavillion

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

20 gearsolutions.com
gear technology requirements and special
high precision parts.
Master Power Transmission, Inc.
www.master-pt.com
Master Power Transmission recently
acquired Baldor Electric Company’s
DODGE manufacturing facility in Colum-
bus, Indiana. Its product solutions help
customers achieve a competitive advan-
tage in varying applications within a broad
variety of Industries. Drawing from more
than 90 years of experience the compa-
ny’s strong market knowledge, talented
staff, established customer relationships,
and rapid response service capability pro-
vide measurable value to its global cus-
tomer base.
Mazak Corporation
www.mazakcorp.com
Mazak Corporation is the North American
manufacturing, sales, and support arm
of the leading international machine tool
builder, Yamazaki Mazak Corporation of
Oguchi, Japan. It produces machine tools
and systems for the precision machin-
ing of metal parts, including CNC turning
centers, horizontal and vertical machining
centers, multi-tasking machining centers,
turnkey cells, and software solutions to
help customers achieve lean, efficient
manufacturing operations.
EDUCATION
Las Vegas, NV
Detailed Gear Design-Beyond
Simple Service Factors
TBD
May
Available Year-Round
Motor & Gear Engineering, Inc.
www.motorgearengineer.com
Motor & Gear Engineering specializes in
the manufacture, design, and engineer-
ing of gear sets and gearboxes, custom
machinery; sales and service of all types
of electric motors, motor drives, and gen-
erator sets. Its services include machine
design for automation, custom automa-
tion equipment, robotics, and CNC turn-
ing and milling, also offering consulting
and general machine shop services.
ProTek Engineering Co.
www.protekeng.com
Proteck is a multi-product engineering
company that manufactures machinery
and software for diverse industries. Their
product lines include printing machinery,
packaging machinery, CNC machine
tools, and CAD/CAM software. Proteck
products are operational in more than 20
countries worldwide.
Regal-Beloit Corporation
www.regal-beloit.com
Regal Beloit, founded in 1955, manu-
factured cutting tools and gearboxes
throughout its first 25 years. During the
last 25 years it has completed 28 acquisi-
tions. This expanded product line reflects
that Regal Beloit products are “At the
Heart of What Drives Your World,” allud-
ing to the fact that most of its products are
necessary—not optional—to the function
of the equipment powering our world.
EDUCATION
Chicago, IL
Basic Training for Gear
Manufacturing
16-20
Online
Workforce
Education
Sandvik Coromant
www.sandvik.com
Sandvik is a high-technology engineer-
ing group with advanced products and
a world-leading position within selected
areas. Worldwide business activities are
conducted through representation in
more than 130 countries. Sandvik’s op-
erations are based on unique expertise
in materials technology and extensive in-
sight into customer processes.
Shute Upton Engineering
www.shute-eng.com.au
Shute Upton Engineering is a major pre-
cision and general engineering business
that maintains and prolongs industrial
equipment. Since 1957 it has delivered
year-round specialist emergency break-
down repair services designed to dramati-
cally minimize customer downtime.
Stack Metallurgical Services, Inc.
www.stackmet.com
Stack Heat Treaters was opened in 1984,
and in 1995 changed its name to Stack
Metallurgical Services. The company
started out with a couple of atmosphere
furnaces and companion draws, but
since then has grown into the most versa-
tile provider of heat treating services in the
Pacific Northwest.
Sunnen Products Company
www.sunnen.com
Sunnen provides precision honing equip-
ment for both the industrial and engine
June
Gain basic gear training in three courses: Fundamentals of Gearing,
Gear Inspection, and Hobbing. Go to www.agma.org/events-training/
detail/online-workforce-education.
building market. It has a system for vir-
tually any bore sizing application, even
submicron tolerances. The company has
also incorporated its experience into a
complete line of abrasives, tooling, and
gages.
The Robbins Company
www.therobbinscompany.com
With more than 50 years of innovation and
experience, this company is a developer
and manufacturer of advanced under-
ground construction machinery. Robbins
has been involved in hundreds of tunnel
boring projects around the world. Today it
offers an extensive range of underground
excavation equipment.
Tokyo Technical Instruments, Inc.
www.tti-geartec.jp
Since its establishment in 1972, the com-
pany has been dedicated to the manufac-
ture of gear measuring instruments. Its
gear testing machines have been contrib-
uting to the manufacture of gears all over
the world through the support by both do-
mestic and overseas customers.
TopGun Consulting
www.topgunconsulting.net
TopGun Consulting is a specialized firm
that focuses on profitability and streamlin-
ing of manufacturing processes. With over
30 years of manufacturing background, it
is positioned to help small and large com-
panies achieve their goals.
Big Sky, MT
Gear Failure Analysis Seminar
27-29
JANUARY 2010 21
AGMA Welcomes New Members of the Board of Directors
AGMA is pleased to announce the appointment of Matt
Mondek of Cotta Transmission as chairman of the board
for 2011-2013, as well as the appointment of Lou Ertel
of Overton-Chicago Gear Corporation as treasurer. The
Board of Directors also welcomes four additions: Sulai-
man Jamal, managing director of Bevel Gears (India) Pri-
vate Limited; Bob Sakuta, president of Delta Gear, Inc.;
Michael Smith, vice president of sales and marketing of
Capstan; and Mike Suter, vice president of marketing of
Emerson Industrial Automation.
Sulaiman Jamal received his degree in mechanical
engineering from P.S.G. College of Technology, Coim-
batore, South India. After his technical education he
worked in the P.S.G. toolroom before joining a bevel gear
company in Bangalore where he was exposed to bevel
gear cutting tools, bevel gear manufacture, and heat
treatement of bevels. He branched out in 1976 to start
his own gear shop and has expanded his business since.
He now is the chairman/managing director of the Jamal
Group of companies, which manufacture a very wide
range of bevel gears—straight and spiral including spiral
grinding/curvic coupling grinding and bevel gear-related
products. He and his wife Christine live in Bangalore and
have three children: Mushtaq, who just finished his MBA
after his mechanical engineering at Calpoly, California;
Adela, a business graduate from San Francisco State;
and Zain, an economics graduate from Claremont McK-
enna, California. Jamal’s other interests include music,
classic cars, and restoring old/antique furniture.
Bob Sakuta has been a partner in Delta Research
Corp. since 1979, and the sole owner 1996. Delta Re-
search is a manufacturer of prototype powertrains and
their components for the automotive, off-road, and spe-
cialty sectors. In 1998 Delta Research began grinding
their gears in-house, which minimized the need to pur-
chase outsourced gears. In 2004 it further decreased
its dependency on outside sources by purchasing Tifco
Gage & Gear Co. In 2010 Tifco’s name was changed to
Delta Gear, and over the past seven years the company
has purchased leading edge equipment and built a team
of highly skilled personnel, making Delta Gear a premier
manufacturing facility of high precision gears. In 2010 the
company relocated to a state of the art facility in Livonia,
Michigan, which will soon house the nation’s first contract
gear metrology lab. With Diane, his wife of 36 years, he
has raised three children. His son Scott and son-in-law
Tony are both partners in the business. Bob graduated
with a BBA degree from Northwood University in Midland,
Michigan, in 1976, majoring in accounting with a minor in
Business Law.
Michael Smith graduated from the State University of
New York. He began his career at Franklin Industries in
the international sales department and moved into manu-
facturing; supervising manufacturing operations in seven
foundries in Taiwan and China. From 1981 to 1989 he
was managing director of Efel North America, an importer
of manufactured cast Iron components from Belgium.
He joined Capstan in 1989 and has been responsible
for all sales and new business development efforts. Cap-
stan is a leading producer of powdered metal gears and
structural components, with four manufacturing facilities
in North America. Professional affiliations include mem-
bership in the Metal Powder Industries Federation and
the Society of Automotive Engineers. In any free time
he enjoys golf and racquetball, and he lives in Wayland,
Massachusetts, with his wife Beth and children Michelle,
Christopher, and Scott.
Mike Suter began his career with Emerson in 1984
upon graduation from Penn State University. Beginning
as a sales rep in the Northeast, he held a variety of sales
management roles in Chicago, Los Angeles, and Atlanta
before moving into marketing with Emerson in 1998. He
currently oversees marketing for Emerson Industrial Au-
tomation gearing, conveying components, chain, and
clutch products, as well as their material handling busi-
ness. He is also responsible for division marketing com-
munications and works out of the power transmission so-
lutions headquarters in Florence, Kentucky. He and his
wife Shirley live in Cincinnati and have two sons currently
attending college.
AGMA would also like to thank outgoing board mem-
bers Ivan Brems, Richard Kuhr, Jack Nowlin, and Bryan
Lammers for their years of service to the association and
the industry.

AGMA Leadership
Board of Directors Executive Committee
Chairman: Dave Ballard
Norbert Benik: VP of Industrial Sales, Ontario Drive & Gear LTD Corporate Manager, SEW-Eurodrive, Inc.
Jim Bregi: President, Doppler Gear Company
Treasurer: Matt Mondek
Ivan Brems: CEO, Hansen Transmission International President, Cotta Transmission Company, LLC
Louis Ertel: President & CEO, Overton Chicago Gear Corp.
Chairman, BMEC: John Strickland
Richard Kuhr: Senior Application Engineer, ABA-PGT, Inc. VP of Marketing and Strategic Planning, Fairfield
Bryan Lammers: Division Manager, Caterpillar, Inc. Manufacturing Co., Inc.

Tom Marino: President & CEO, Gear Technology Chairman, TDEC: Dr. Phil Terry
Gordon New: Managing Director, Ronson Gears Pty., Ltd. Metallurgist, Lufkin Industries

Jack Nowlin: President, C-B Gear & Machine, Inc. Chairman Emeritus: Dennis Gimpert
President, Koepfer America, LLC
Bob Phillips: Senior Vice President, Gleason Cutting Tools Corp.
Kyle Seymour: President & CEO, Xtek, Inc.
Staff
Dirk Wernecke: Global Manager, Pricing, The Timken Company Joe T. Franklin, Jr., President
Charles Fischer, Vice President Technical Division
Jan Potter, Vice President Membership

Contact the AGMA General requests: webmaster@agma.org

1001 N. Fairfax Street | Fifth Floor Membership questions: membership@agma.org
Alexandria, VA 22314-1587 Gear Expo information: gearexpo@agma.org
(703) 684-0211 Technical/Standards information: tech@agma.org
22 www.agma.org
gearsolutions.com AGMA Foundation: foundation@agma.org
 siteSAFETY
terryMcDONALD
Member of the ANSI Subcommittee on Gear Safety
The improper handling of cutting tools with
sharp edges isn’t the only way they can cause
injury, as manufacturing flaws or environmental
influences can cause breakage.
cerned about here is how to improve the safety for
Spring has finally sprung! Isn’t that one of the nicest things you’ve our employees.
read today? Just think, it’s the start of grilling season (remember to follow
all the proper safety procedures when doing so), the start of fishing season
(don’t hook yourself), camping season (look out for snakes), baseball season
(don’t get beaned by a flyball), and vacation season, where it’s just a good
idea to be careful in general. All of these things are what we look forward to
during the long months of winter, but spring also brings some things that are
not so welcome. Allergy season starts now, and some of our employees are
very much affected by allergies this time of year. This poses a very real threat
to our production schedule. So what can we do about it?
As we discussed last month, we must make every effort to keep the work-
place air clean and free of particulates that will cause allergies, or even more
serious breathing problems. We should have personal protective devices avail-
able for our employees who need them and do all we can to create a clean
and healthy working environment. It is probably a good practice to have oxygen
available in some form for emergency purposes, along with some medications
to alleviate allergy symptoms when they become uncontrollable.
I would also highly recommend that if you do not have trained personnel
designated as first responder that you immediately designate this position and
see that they obtain the proper training. This training is often offered by local like, what the blank that is correct looks like, and
fire departments and police departments, as well as local community colleges.
You can also check with your local Red Cross or Salvation Army. Typically the
training is free, or available at a very minimum cost. One thing to remember
is that it is less expensive to have an employee miss work due to illness than
to have an injury due to his or her inability to perform properly due to illness.
Allergies have become a very real safety issue due to the very large increase
in people affected.
One of the issues discussed elsewhere in the magazine this month is cutting
tools. These tools are another very real safety hazard that is often ignored. operation. Most guarding solutions that I see rely on
There is, of course, the standard issue of the sharpness or dullness of tools
that present a handling issue. But there is another issue that we must stay happen without the proper training. Remember,
About the author:
Terry McDonald is partner and manager of Repair Parts, Inc., and a member and
past–chairman of the ANSI B11.11 Subcommittee on Safety Requirements for
Construction, Care, and Use of Gear Cutting Equipment. Contact him at (815)
968–4499, rpi@repair–parts–inc.com, or [www.repair–parts–inc.com].
24 gearsolutions.com
aware of, and this is the danger of using a cutting
tool that has been damaged. The damage can occur
during the manufacture, the resharpening, or even
just while handling the tool. All of us who have
been in the gear cutting industry for an extended
period have seen instances of a cutting tool break-
ing during use. There are so many things that can
cause this breakage that it would be very difficult
to list them all. Suffice it to say that the tool, the
blank material, the setup of the machine, the tool-
ing holding the piece, the feeds and speeds being
used, and the coolant are some of the reasons for
cutting tool breakage during use. What we are con-
“There is another issue
that we must stay aware of
besides sharp edges, and
this is the danger of using
a cutting tool that has been
damaged."
The number-one item, in my opinion, is proper
training for your employees. They must know what
to look for in the use of any cutting tool in order to
have the optimum safe experience. They need to
know what a properly sharpened cutting tool looks
what the proper setup on the machine looks like.
This does entail some training on the part of the
employer, but again this is much less expensive
that an injured employee.
Of course, safety guarding is another area of
concern, and one that most people would probably
put first. It is my contention that without the proper
safety training, you cannot “idiot proof” a machine
the operator using them as intended, and that can’t
operators often see guarding as an impairment to
the most efficient operation and therefore neglect
to use them, or use them improperly. I believe that
depending upon guarding to protect the employee
without properly training them leads to a false
sense of security.
 TOOTHTIPS
Electro Chemical Machining (ECM) is the controlled
dissolution of material from the workpiece by contact with
a chemical reagent in the presence of an electric current.
It is a relatively stress-free process that can be improved
williamCrosher by shot peening to improve surface imperfections and
Author, engineer, and former director of the grain boundaries affected by the chemicals. A recast
National Conference on Power Transmission layer is produced that can be brittle and notch sensitive
under residual tensile stress. The chemicals used
Material removal doesn’t always involve blades, as there can attack the grain boundaries. Surface improvement
techniques can be used to eliminate these defects.
is the Electric Discharge Method, Electro Chemical These include surface hardening, honing, surface rolling,
Machining, and laser and abrasive water jet machining. polishing, and shot peening.
Lasers can be used to cut gears with precision,
depending on the material. The method is slower than
traditional techniques. CNC machines control the laser’s
path to cut the maximum number of gears from a metal
The Electric Discharge Method (EDM) is based on an electrically conductive sheet. Once checked and set the operation needs a
material being eroded by a continuous spark discharge to its surface. Using special minimum of supervision. A disadvantage is in having
generators, pulsed DC or AC current is used to vaporize and melt away the conductive
material. The electrode that delivers the heat can be a small diameter wire or a pre-
shaped solid electrode. The spark gap must be flushed with a dielectric fluid. With
EDM a wire is continuously fed through arms that are suspended above and below
the gear blank. The process is relatively slow. However, the servo-controlled tooth
“Many of the problems
path is accurate and relative to that of a CNC machine tool. Many of the problems
associated with the traditional methods of manufacturing gears—such as chatter,
associated with the
rigidity, material hardness, tool selection, chip thickness, etc.—have been eliminated.
EDM also has the advantage of being programmed so that a number of machines can
traditional methods of
work virtually unattended. Close dimensional accuracies such as 0.0001" and surface
finish of 16 µin are possible with careful application and multiple finishing cuts. Further
manufacturing gears—
improvements are obtained by running in the gears. It is a useful method for producing
special gear prototypes but will not replace traditional methods. It is not applicable chatter, rigidity, material
to the normal production gear. It also has its own set of problems, but it can simplify
the design and manufacture for certain special applications. For example, when a hardness, etc.—have been
particularly tough high-strength material such as maraging steel is used, the hardness
specification precludes any finishing operations. EDM allows for a variety of shapes eliminated.”
and sizes, allowing maximum flexability for making prototypes.
The process has considerable flexibility in that the sizes and geometry can be easily
changed, whereas special hobs or cutters would be needed in alternate manufacturing
heat-affected zones at the edges of the cut. Heat
methods. Because the material is not removed by cutting, the blank does not have
distortion is not eliminated, and there may be a need
to be as rigid. It is not at this time an economical method. It has been useful in the
for further machining. Materials such as aluminum and
manufacture of plastic gear molds. The involute shape can be accurately produced,
copper alloys that are highly reflective are difficult to cut,
as can tip relief, root relief, and non-involute forms. Spur gears to 5 DP and bevel
as they affect the focus of the beam. Maximum material
gears have been manufactured to this system, which is still in the early days of its
thickness is 0.75" because too much power is required
development. Profile inspection indicated a similar tolerance accuracy was possible
for thicker materials. Most tooth forms such as worm,
for the large coarse pitch gears as it was for the fine pitch. Surface finish of up to 16
bevels, and helicals can be produced with a laser method
micro-inch are attainable with multiple skim cuts with low powers.
due to the latest developments in CNC controls.
In the early part of 1980 a versatile method for
About the author: producing prototype or small run gears by abrasive water
William P. Crosher is former director of the National Conference on Power jet was introduced. The water stream creates a vacuum,
Transmission, as well as former chairman of the AGMA’s Marketing Council and
drawing a finely grained abrasive into the mixing chamber.
Enclosed Drive Committee. He was resident engineer-North America for Thyssen
Gear Works, and later at Flender Graffenstaden. He is author of the Unlike the laser method, it can cut through stacks of gear
book Design and Application of the Worm Gear. blanks. Burr-free edges without heat-affected zones are
produced.

26 gearsolutions.com
 HOTSEAT
jackTitus
Director of process and developmental
engineering, AFC-Holcroft
In response to an increased interest in high-pressure
gas quenching (HPGQ), the author addresses the
issue in this month’s installment.
Hydrogen for high-pressure gas quenching (HPGQ) has the highest
thermal conductivity and heat capacity of any commercially available gas, but
currently is not used due to safety concerns in commercial high pressure cooling
applications. Somewhere, however, in a secret laboratory it receives research
activity. A truly inert gas, helium is the next best choice, with a very good
combination of thermal conductivity and heat capacity (specific heat, Cp). Nitrogen
is a distant third, as indicated below:
GAS DENSITY [p] THERMAL CONDUCTIVITY [K] SPECIFIC
HEAT [Cp]
[Lb./cu.ft] [BTU/ft./hr./°F BTU/Lb./°F
HYDROGEN 0.0056 0.10 3.38
HELIUM 0.01 0.082 1.24
NITROGEN 0.078 0.015 0.25
Helium’s ability to transfer heat away from a part is 5.5 times greater than
nitrogen, and once heat energy is in the gas helium can hold five times as much.
In either case, however, if the velocity of gas passing over the part is not uniform
or does not exceed the thermal conductivity of the steel, the rate of heat removal
will not be equal over the gear and the martensitic transformation will occur at
different times, resulting in distortion and likely NMTP.
Nitrogen’s density is 7.8 times that of helium. Translated: fan horsepower (HP)
for nitrogen must be 7.8 times higher, and then add 20-bar pressure (290 psia,
275.5 psig), and the horsepower difference is huge. Fan motor HP increases
proportionally with pressure (gas density), and increases by the cube of the
difference in RPM; double the RPM and the HP goes up eight times. Since gas
velocity is also critical, fan output (RPM) must be high to transport heated gas to
the water-cooled heat exchanger and back to the load. Even for helium, to move
the quantity of gas through the load sufficient to quench alloyed steel gears,
almost 400 horsepower is required. Employing the same HP for heavier nitrogen
necessitates lower recirculation volume (smaller fan ,or lower RPM) to stay within
400 HP. And since nitrogen already has significantly lower heat transfer properties,
About the author:
Jack Titus can be reached at (248) 668-4040 or jtitus@afc-holcroft.com.
Go online to [www.afc-holcroft.com] or [www.ald-holcroft.com].
28 gearsolutions.com
combined with lower gas recirculation volume one can
see its limitation. Consequently, only very high-alloyed
steels—and thus more expensive—or certainly smaller
cross-section gears qualify for nitrogen quenching.
The downside to using helium is the cost. At $25.00
per 100 cu. ft. it must be reclaimed, while nitrogen is
only about $0.50 per 100 cu. ft. and can be thrown
away after each cycle. Say you want to harden a
2-inch cross-section AISI 5130H gears, here’s how to
determine if you can:
1) G o online and type “Timken practical data for
metallurgists” and download the pdf file;
2) Go to page 56 and note the box containing “H
value,” “quench,” and “agitation”;
3) 20-bar helium quenching, not shown, falls in at
about 0.30 similar to very low agitated oil;
4) On the same page find the 2” diameter bar or
one that comes closest to your part or gear cross-
section;
5) F ind the surface, ½ radius or center line and
interpolate where 0.30 intersects that line and
read down to the corresponding Jominy distance
shown;
6) 2” bar at H = 0.30 intersects the “center” line at
about 13.5 Jominy distance;
7) Now go to page 47 and locate 5130H steel. There
the max./min. hardness is shown for the Jominy
distance 13.5 is 20.5 to 34.5 Rc;
8) If your core hardness requirement is 32 Rc, then
you likely can’t use the standard 5130 H steel
but must specify a restricted hardenability (RH)
chemistry that results in a Jominy hardness range
no lower than 32 Rc. Final hardness is lowered by
tempering;
9) If nitrogen is your HPGQ gas of choice it has an
approximate H value of slightly less than 0.20;
10) Using the same 5130H Jominy table the surface of
the 2” gear would barely make the core hardness
using helium gas. This will force you to upgrade to
a much more expensive alloy.
Having gone through the above, it will become
obvious to those skilled in the art that in many
instances the core hardness of the gear cross-section
may not be the critical parameter, but the core of a
tooth. Here two locations are important: tooth center
on the pitch diameter (PD) and midpoint on a line
drawn from root-to-root. Only empirical testing will
confirm HPGQ suitability for any material. And when
a suitable material is selected, a trial and error test
plan including part location within the loading scheme
will be required.
 COMPANY
PROF ILE
Banyan Global
Technologies,
LLC
With decades of
combined experience in
the gear manufacturing
market, this company
is taking a specialized
approach to serving its
customers.
By Russ Willcutt

30 gearsolutions.com
Anyone who works in the gear manufacturing indus-
try knows that it is a world unto itself, with its own
language, history, techniques, processes, and cast
of knowledgeable characters. Anyone who has tried
entering that world under false pretenses knows they
will be found out, and the charade will not last. In
many ways, that understanding is central to the phi-
losophy of Banyan Global Technologies, according to
one of its founders.
“A few years ago Jeff Kaplan and I realized that we
were both looking for something new,” according to
Darryl Witte, vice president of sales for the Midwest
United States, adding that his partner holds the same
position covering the Southeast. “My specialty is cut-
ting tools, and his is abrasives. We’d both spent years
acquiring knowledge and honing our skills, and we
came to the realization that there was a market need
we could fill.”
In short, their gear-specific backgrounds would be
an asset to customers seeking abrasive materials and
tooling for their specific application, and if it could be
sourced in the United States, all the better. “We could
find cheaper manufacturers overseas, but that’s not
what we’re aiming to do,” Witte says. “You’re not real-
ly saving money by purchasing an inexpensive cutting
tool that won’t last very long and isn’t designed for
the job you’re doing. We don’t just want to provide our
customers with a tool, we want to make sure they’re
using the right tool.”
That’s why one of the first details reviewed when
dealing with a new application is to determine exactly
what they’re looking for: the lowest price, the highest
quality, or the best cost per piece. It also helps to
have a “behind the scenes” understanding of how the
purchasing process is conducted.
“Quite often you’ll find that there’s a breakdown in
the lines of communication between people who are
motivated by different things, or have different con-
cerns,” he says. “The engineering group may be inter-
ested in a cutting tool of a particular material and de-
sign, while the purchasing agent is more focused on
the unit pricing, wanting to save his or her employer
money. Both of those concerns are completely legiti-
mate, but the good salesman knows how to ask the
right questions in order to address those concerns
and make sure everyone gets what they need.”
These skills are brought into play when Witte and
Kaplan are discussing the cutting tools and carbide
inserts they design themselves and market under the
To learn more:
Call (815) 786-5986 for Witte, and (864) 382-0695 for Kaplan.
Send e-mail to sales@banyangt.com, or go online to [www.banyangt.com].
Banyan brand name. Other Banyan
products include a gear-chamfering
robot (GCR) that is ideal for deburr-
ing ring gears used in the wind indus-
try, or other large gears for markets
such as mining and construction
equipment. A newly developed tech-
nology, the first GCR has been sold
and is currently being put through its
paces. “There’s a lot of technology
onboard,” Witte says, “and it’s ‘pro-
gramless’ so that you don’t have to
input a lot of data. The machine is
very flexible and can chamfer both in-
ternal and external gears without the
need for long setup times.”
Based in South Carolina and estab-
lished in 2007, Banyan – named for
the giant tree that symbolizes power
to many cultures – Global Technolo-
gies’ administrative activities are
handled by Jay Adams, vice presi-
dent of operations, while Kaplan and
Witte spend most of their time in the
field. The company is something of
a hybrid, with the partners private-la-
beling the products they’ve designed
and acting as representatives for
other companies providing abrasives
and specialized tooling. The key at
this stage of the game is to have a
broad product line so that custom-
ers have options, and the partner’s
45 years of combined experience is
helping open doors as they make
the case for their highly tailored ap-
proach to doing business.
“We respect our customers and
feel that we can provide them with an
important service,” Witte explains.
“We’ve done our homework, we know
this industry. And while we’re always
going to give our customers what they
want, we’re also going to do our best
to advise them about what they might
actually need. We see ourselves as
partners, helping our clients achieve
their goals, because that’s how we
reach our own goals as well.”
Better Bevel
Gear Production
By Michael Hayes

Fig. 1: Chamfering in paral-

lel to cutting saves precious
cycle time.
Gleason’s newly designed
Phoenix 280C bevel gear
cutting machine is faster and
easier to use than ever before,
providing dependability and
boosting productivity.

G
Gleason revolutionized bevel gear production in 1989 with the introduction of
the first fully CNC controlled cutting machine, called the Phoenix® 250HC. In
2001 the Phoenix II was introduced, featuring a breakthrough monolithic column
design that optimized dry machining, significantly reduced floor space require-
ments, and greatly improved cycle times. Now, with the introduction of the third
generation of Phoenix technology and the 280C bevel gear cutting machine,
bevel gear manufacturers again stand to benefit from a host of new features
and capabilities. For automotive manufacturers requiring faster production of
today’s higher-quality, quieter-running gearsets, the 280C delivers significantly
shorter cycle times. For precision job shops producing gears in smaller lot sizes
where more flexibility is desirable, the 280C enables them to change over from
one part type to the next in a fraction of the time it would normally take. And
for any user the new design makes the 280C among the easiest of machines
to operate and maintain day to day. The following article provides an in-depth
look at the 280C’s new design features and capabilities.

Reducing Nonproductive Time

CNC controls, powerful direct-drive motors for high-speed cutter and work spindles, and new cutter
system designs have all combined in recent years to make significant improvements in overall machine
cycle times. Improvements in these areas going forward, however, will likely be incremental. That’s why
Gleason engineers have increasingly focused on essentially the last remaining area where significant
cycle time savings can still be made today: nonproductive time. With the introduction of the Phoenix
II in 2001, Gleason took a small bite out of nonproductive time with a new monolithic column design
and pivoting cutter head that put the cutter and workpiece in closer proximity, thus shortening machine
 HOBS for Involute
spline DIN 5482

– Complete line of Gear Tooling.

– Cutter Body Reconditioning to O.E.M. Specifications
and Cutter Body Maintenance Program.
– Resharpening and Recoating Service, Hobs and Shapers.

Blade Sets for

Spiral & Hypoid Gears

Hub type gear

NEW and RECONDITIONED shaper cutter

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Same O.E.M. Quality,

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shaper cutter
 “Providers of world class gear
tooling with first class service,
quality and performance”

ETC
Engineered Tools
Corporation
2710 West Caro Rd.,
Caro, MI 48723
PH: (989) 673-8733
FAX: (989) 673-5886

Engineered Tools
Corporation
Engineered Tools Corporation 1307 E. Maple Rd., Suite “G”,

engineeredtools.com
Troy, MI 48083
PH: (248) 619-1616
FAX: (248) 619-1717
 motions. But the new Phoenix design goes much further. In addition
to a monolithic design, the 280C also features:
Chamfering in parallel to cutting: Chamfering has traditionally
been a significant challenge in bevel gear production because after
cutting chamfering generally requires that the gear be removed and
loaded into a separate chamfering machine or, on some machines,
done on the machine but sequentially to cutting, thus adding to

Methods engineering services company or contract

methods engineers with expertise related to gear
manufacturing

Moog Inc. is a worldwide manufacturer of precision control systems.

Our Torrance facility specializes in gear applications and is looking
to augment our methodizing capabilities on a contract basis.

Required capabilities include:

- determining manufacturing
procedures
- establishing operations sequenc-
ing and writing detailed opera-
tions sheets
- preparing and proving out N/C
programs
- establishing time standards
- preparing tooling and gauging
lists
- expertise with gears, ring gears,
bevel gears, splined shafts, carriers and housings

For more information please send your contact

and company or background information to:
Pdealleaume@moog.com - Subject: Methods
Fig. 2: Workholding changeover is easy and tool-less.

36 gearsolutions.com
overall cycle time. But the 280C design completely eliminates the
time normally required for chamfering. The machine is equipped
with an auxiliary chamfering spindle that allows a part to be cham-
fered in parallel to a part being cut. Even time-consuming chamfer-
ing of both the toe and heel of the gear can be easily completed
without adding to cycle time.
Automated parts load/unload: The 280C is additionally equipped
with a high-speed parts loader that automates the process of
moving ring gears and pinions from the cutting spindle to the
chamfering station. The double-gripper design enables the loader
to simultaneously grip, and then exchange parts, in as little as
five to seven seconds.
Quick-change tooling: In an increasing number of production
environments, batch sizes have gradually become smaller to
better meet fast-changing customer demand, shorter delivery
schedules, and reductions in inventory. With the 280C consid-
erable effort has been focused on simplifying the often slow,
tedious process of changing over both the cutter system and the
workholding to accommodate new part numbers. As a result the
280C is the first machine of its kind with a hydraulic cutter change
mechanism that completely eliminates tooling. Instead of using
wrenches and special parts for cutter removal, the 280C operator
can quickly and easily remove and replace a cutter system with
the touch of a button, in a fraction of the time and effort. When it
comes to making a workholding change on the work spindle, the
280C similarly simplifies and speeds the process for the operator
by enabling him to remove the workholding from the front of the
machine without the use of any tools, rather than the typical pro-
cess of first accessing the back of the machine and using special
tooling to remove a series of fasteners.

Fig. 3: The new PENTAC PLUS cutter extends tool

life and boosts productivity.

APRIL 2011 37
 Advances in
Bevel Gear
Cutting Systems
The Phoenix 280C can be equipped with several new
bevel gear cutting systems that enable users to take full
advantage of the machine’s capabilities. For example,
users can manufacture higher quality straight bevel gears
in less time, with higher accuracy and repeatability, using
the new Gleason CONIFLEX® PLUS cutters. When running
on the Phoenix 280C, CONIFLEX PLUS is said to be the
most productive solution ever offered for straight bevel
gear cutting. Here’s why:

• The use of PENTAC® carbide blades with advanced

coatings allow wet or dry cutting at cutting speeds as
high as 305 meters per minute (1000 sfm). Tool life is
considerably greater too: up to 1000 parts can be cut
before sharpening, with an estimated 100 sharpenings
per blade.

• CONIFLEX PLUS can be used in conjunction with

Gleason’s advanced Formate cutting process, which
improves cutting speed while providing enhanced rolling
capabilities with higher effective contact ratios.

• Gleason G-AGE CONIFLEX correction software, com-

bined with the electronic summary transfer and storage
capabilities of the Phoenix machine, combine to reduce
part changeover and setup times by up to 80 percent
as compared to straight bevel mechanical machines.

Gleason has also improved on its popular and produc-

tive PENTAC cutter systems, for both face hobbing and
face milling applications. With introduction of the PENTAC
PLUS system users benefit from significantly higher tool
life and productivity—an ideal solution for medium to high
volume production challenges and, in particular, dry high-
speed cutting.

38 gearsolutions.com
 Intuitive Operator
Interface
In the development of the 280C, Gleason
software and control engineers also recog-
nized the need for a powerful but simple and
extremely user-friendly operator interface.
This would help empower a new generation of
even less-experienced operators and enable
them to easily optimize the full range of
bevel gear processes, whether face milling,
face hobbing, or straight bevel gear cutting.
The use of a new Gleason “Global Software
Platform,” in conjunction with Siemens 840D
CNC controls or Fanuc 30i and running in a
familiar and highly intuitive Windows envi-

Use your smartphone to download

the Bevel Gear Solutions PDF

Built for Performance

As completely dry machining has become
more common, so too has the need for
improving thermal stability and dry chip con-
tainment. The 280C’s monolithic column
design enables hot dry chips to easily fall
completely clear of the machine structure into
a simple chip conveyor, in a work chamber
that’s remarkably free of exposed rails, wires,
or hoses. The thermal effect of the chips on
the machine structure, and their impact on
day-to-day maintenance, is greatly reduced.
The monolithic column is also cast from a
polymer composite material rather than typi-
cal cast iron, making it exceptionally stiff and
rigid with very high thermal stability ideal for
completely dry machining. In addition, the
280C features a simplified guarding design
that makes it easier for maintenance person-
nel to access service areas. New features
like a servo door system with robust rails
further improves reliability, as compared to
conventional pneumatic door systems.

APRIL 2011 39
 Fig. 4: The Gleason Phoenix 280C.

408.723.0700
270 Hillsdale Avenue | San Jose, CA 95136
Fax: 408.723.0710
E-mail: info@ws2coating.com
www.ws2coating.com

40 gearsolutions.com
ronment, has put a wide range of powerful plays the status of components where a to troubleshoot or help make repairs, thus
capabilities right at the fingertips of any problem is most likely to occur and then solving many problems before they result
operator. For example, they can quickly provides easy access to materials needed in significant downtime.
create and modify the ideal program for
any gear using a menu-driven data entry about The author:
session with parameters already defined. Michael Hayes is president of Hayes Marketing, which represents the Gleason
Then, during production, operators ben- Corporation. More information is available by calling (585) 473-1000 or visiting
efit for a dynamic display showing all [www.gleason.com].
the most critical information they need
to manage and, if necessary, improve
every aspect of the process. In addition,
a diagnostics screen continuously dis-

Fig. 5: The clean work chamber is

ideal for dry cutting.

APRIL 2011 41
 Clamping Large
Turned Parts
By Steve Hartung

Many industries, such

as renewable energy,
require large parts, so
machine shops should
review their workholding
equipment to make sure
they’re up to the task.
 I
Increased demand for large-size parts such as
gears and turbine blades, mostly coming from the
energy sector, requires machine shops to reinves-
tigate their clamping methods. Machine tool devel-
opment kept up with the demand, but the clamping
technology is still mostly manual, which is time
consuming and requires a lot of maintenance.
The three-jaw power chucks achieve high clamping
forces of up to 50 kN (120 000 lbs) and a repeat
accuracy of less than 0.003 mm (0.0001”). Highly
deformable components such as bearing rings,
gear components or rail wheels can be machined
on six-jaw compensation chucks, which consider-
ably improve the roundness of these workpieces.
These chucks can be switched from self-centering

Chucks for Precision mode to compensating mode. On request, many

large chucks can be modified according to the
During the turning of clamping diameters of up to
customer’s specifications. Some customers order
2.000 mm (79”) there is a tendency to choose
lathe chucks surface ground, provided with tapped
more flexible and efficient three- or six-jaw chucks.
and drilled holes to use them as a faceplate.
The reason for that is simple: Even large compo-
These large-size chucks deliver the highest accu-
nents need to be very precise, which can only be
racies, even in the heaviest applications. Besides,
achieved by using corresponding precision lathe
these chucks are much better sealed than conven-
chucks. In the past large precision chucks were
tional mechanical devices so that even very small
too expensive. Due to standardization of large-size
chips, dust, or tremendous amounts of coolant
chucks, SCHUNK can now offer very competitively
cannot penetrate the chucks. Especially in the
priced solutions for this industry.
case of large clamping equipments, a safe instal-
Extra-large precision chucks are used wher-
lation is extremely important. Ideally customer
ever workpieces with large diameters have to be
service should train the staff on how to handle the
clamped safely and machined precisely, such as
chuck. This will guarantee a worry-free operation
tube ends for the oil industry, thread drill bits,
for many years.
graphite blocks, rail wheels, pump and valve
housings, gearwheels, and many other precision
parts. The lathe chucks for large components from Magnetic Technology
SCHUNK can be used on every known lathe. They An alternative to the high-precision chucks are
are suitable for vertical and horizontal applications, those with magnetic clamping technology. For
and help to reach any high precision requirement. machining ring components, the radial pole plates

The ROTA-S plus features

quick-change jaws, inside
oscillation, and individual
base plates with balance Fig. 1: Highest clamping force, largest jaw stroke, lowest height—all three factors are
weights. optimized by the ROTA NCO.
Fig. 2: ROTA NCR for huge gear units, rings, and other deformation-sensitive workpieces.

44 gearsolutions.com
offer many advantages. Large turned parts can be clamped quickly, safely,
and without deformation. With a multilevel holding force adjustment, work-
pieces can be easily aligned on the magnetic chuck. The so-called hybrid
chucks work even more efficiently. Here the technology of a conventional
three- or six-jaw centering chuck merge together with the technology of
radial pole magnet. With these chucks, workpieces are automatically cen-
tered for fast ID or OD clamping. Hybrid chucks that are used on lathes
with pneumatic or hydraulic actuation can reduce the set-up times up to
80 percent and thus contribute to a considerable boost in productivity.
Fig. 3: Hybrid chucks like the ROTA NCM combine a
centering chuck with radial pole plates.
Fig. 4: The spindle of the SPK jaw box is completely
sealed, making it particularly robust and long lasting.
46 gearsolutions.com
In order to achieve optimal results, the radial pole magnet up to diam-
eter 4000 mm (158”) should be made out of one piece. This assures
extreme stability during the clamping operation. SCHUNK offers a full line
of supporting product such as demagnetizers to ensure that the parts do
not have any residual magnetism after machining.
Clamping Large Components
Although high-precision jaw and magnetic chucks have become more
important in the past few years, large or asymmetrical parts are mostly
clamped on faceplates. This applies all the more for large components
with diameters of about five meters, as they are used for marine
engines, wind power stations, power station turbines, or in the engineer-
ing plant. Normally vertical lathes are used for components of this size,
where the faceplates serve as a workpiece support. This way, gigantic
diameters of up to 75 ft are feasible.
Faceplates from 1.000 mm (40”) and larger faceplates with a diam-
eter of more than 3.000 mm (9 ft) are mostly equipped with parallel
running T-slots. Screws and T-nuts can be mounted into the T-slot guid-
ances and provide stability to the jaw boxes. In order to increase safety,
they are additionally form-fit connected with faceplates using a cross bar.
Normally large faceplates are provided with at least four double T-nuts for
four jaw boxes. If very large and complex or heavy workpieces should be
machined, sometimes six, eight, or more jaw boxes can be used.
Conventional jaw boxes consist of a cast housing, an adjustment
spindle, and hard stepped jaws. By offsetting the double T-nuts manu-
ally they can be individually adjusted to the workpiece. That way it is
possible to clamp various differently dimensioned workpieces safely.
The jaw boxes are mounted next to the workpiece, and the jaw boxes
are then offset as far as necessary by the spindles, until the workpiece
is safely clamped.
Jaw Box Efficiency
Enormous efficiency potentials are hidden in conventional clamping tools
and devices, and it is proven that the modern steel jaw boxes, where
the spindle drive is completely encapsulated, offer a huge advantage
over their cast iron predecessor. An integrated lubrication system, a
maintenance-free design, and all-sided hardened functional parts mini-
mize wear, assure a permanently high accuracy, and assure long life of
the drive spindle. In contrast to the conventional versions, modern jaw
boxes have a lower profile, which allows for better use of the machine’s
working area.
The users should pay special attention to the jaw interfaces. If the
base jaws are equipped with tongue and groove and standard jaw
connections, conventional standard jaws can be used, which reduces
expenses considerably. Operators gain additional flexibility by clamping,
if using the clamping surface on the face of the base jaw. Such addition-
al interfaces allow stable setups close to the surface of the faceplate.
The dimension of the development potential of jaw boxes is shown by
the trend-setting SPK jaw boxes from SCHUNK, which fulfill every require-
ment for a highly efficient workpiece clamping. The large jaw stroke of
up to 100 mm, and the enormous clamping force of up to 180,000 lbs
Fig. 5: Jaw boxes of the future: the sophisticated SPK assures efficiency during the machining of large turned parts.
using low tightening torques provide a safe ID
or OD clamping. During the clamping operation,
the jaw stroke can be read from a clearly visible
scale, which increases the safety of clamping.
Since the distance of the gauge is variable,
these jaw boxes can be used for every face
plate with parallel running T-slots.
In order to expand capabilities and meet
about The author:
new market requirements, machine shops
should reinvestigate their clamping methods. Steve Hartung is service manager
at SCHUNK, a competence leader
Upgrading to handle clamping the large parts
in clamping technology and gripping
required by industries such as renewable systems. Go online to
energy will expand both capabilities and a com- [www.schunk.com].
pany’s customer base.
APRIL 2011 47
Milling Tools
for Bevel
Gears
By Guenter Wermeister

Close collaboration
between industry
partners creates efficient,
productive, and high-quality
solutions for gear milling,
according to Sandvik
Coromant.
C
Curved bevel gears are one of the most com-
plex components in mechanical engineering,
and special machines and tools have there-
fore been required to make them. The most
significant disadvantages for manufacturers
are the cost for expensive machinery, the
large amount of programming, and the time
involved. In particular, this has big effects on
the production of small and medium batch
sizes because the investment cannot be
paid off as quickly as it can with large batch
production. There are also growing demands
on producers of gears to ensure that their pro-
duction processes are cost-efficient, produc-
tive, and of the highest quality in order to fulfill
the customer’s demands for durability and
price, and to therefore remain competitive.
Of the various manufacturing procedures
for gears milling applications are the most
widely used, whether with special cutting
heads and expensive special machines or
with end mills on five-axis machining cen-
ters. Both procedures are complex and
costly, but they also have a great potential
for improvement.
Potential for
Productivity
To exploit this potential Wolfgang Huetter,
head of production at VOITH Turbo in
Germany, worked with two selected suppliers
as partners: Gebrueder Heller, and Sandvik
Coromant. They tackled the challenge togeth-
er, phrased by Huetter as “A long-lasting and
Fig. 1: Turn milling the outer contour of a gear wheel using a Sandvik
Coromant standard tool in a Heller machining center.
efficient solution must eliminate the current
disadvantages of both procedures, combine
their advantages, and create a new solution
that significantly improves the production
of bevel gears in small and medium batch
sizes.”
The solution for machine tools lies in using
flexible five-axis machining centers instead of
special machines. With this solution manu-
facturers can also carry out other machining
operations and different components. To also
reduce tool costs, the focus had to be on cut-
ting tools that can be used flexibly as dedicat-
ed form mills. In this case the only tools worth
considering are standard tools that can be
fitted with standard indexable inserts. In addi-
tion to a machine and tool layout that reduces
costs and ensures a satisfactory degree of
flexibility, the optimum solution must make
sure that the required quality levels are met
and that the maximum possible level of reli-
ability is achieved. The solution should also
ensure an increased metal removal rate, and
thus reduced machining time, especially dur-
ing soft machining.
In their work to arrive at the solution, the
project partners thought outside the immedi-
ate box. Although the milling of gears was
the focus of the optimization measures,
the entire process chain for soft machining
was called into question and re-evaluated.
The partners involved then agreed that a
key objective of the development project—to
increase productivity and cost efficiency—
should mostly be achieved by the increase in
the metal removal rate. The result of this col-
laborative work, “uP-Gear Technology,” now has
a patent pending.
Creating Perfect
Conditions
With this new development rough cuts were
processed first, with standard milling cutters
used with a feed rate of above 2000 mm/min,
providing metal removal rates of up to 400
cm³/min. The resulting cutting pressure puts
a large load on the machine and, in addition,
workpieces can weigh up to several hundred
kilos. The choice of machine had to have speci-
fications to well withstand the load conditions
involved—specs including tool, main spindle,
and rigidity of workpiece clamping.
The final choice was a Heller high-perfor-
mance machining center capable of five-axis
simultaneous machining, where stability and
performance combined to provide the best con-
ditions for the potential increase in output. The
machine offers user-friendly NC cycles integrat-
ed into the machine controller for entering gear
parameters. This eliminates the need for exter-
nal programming to be carried out in CAD/CAM.
Any necessary corrections can be made easily
using parameterized input from the operator.

Leaders
Problem-free manufacture is also possible with
the alternating machining of housings, bevel
gears, and other components, emphasizing

in Gear Workholding for Over

the required flexibility and performance of the

60 Years
machine, which can be enhanced even further
using pallet or robotic automation.
The uP-Gear Technology takes place from the
first machining operation. In previous machining
Drewco Offers procedures, the outer contour of the workpiece
European Quality was first machined on a turning center in two

Workholding separate setups. But these operations have

been switched to turn-milling on the machining
center. This means that the bevel gear’s outer
contour and the spiral gearing are totally com-
pleted in just two setups. A welcome bonus is
that absolute concentricity is achieved between
- Design and Build of Custom Tooling the bevel gear contour and the gearing. This
significantly improves the quality of the finished
- Outstanding On Time Delivery
components as well as saving machine time.
- Consultations and Installation The extensive range of tools and experience
- Rush Order Capability from turn-milling provided by Sandvik Coromant

- Set Up Reduction Solutions

as a partner has made it possible to exclusively
use standard tools with cutting data that com-
- Attractive Pricing
pares favorably with the previous turning opera-

Drewco designs and

builds European
quality tooling and
combines it with
short lead-times and
attractive prices.

This is why so many manufacturers now buy their

machines from Europe and their workholding for those
machines from Drewco.
Be a Hero In Your Own Company

Don’t wait for expertly designed &
manufactured workholding
262-886-5050 | service@drewco.com | www.drewco.com
Chucks | Arbors
Mandrels | Collets
Grinding | Hobbing
Shaping | Shaving
Fig. 2: Roughing milling of tooth-spac-
es on a bevel gear. The high-perfor-
mance rough machining of the tooth
spaces takes place in several steps
using dedicated Sandvik Coromant
standard milling cutter with standard
indexable inserts.

50 gearsolutions.com
tion. The complete machining process means
less idle time is clocked up, less setup time
is needed, and less transport-time, as well as
much simpler planning of machine utilization.
Redefining Machining
The next machining step, that of milling gear
tooth spaces, was also completely redesigned.
These were previously created by milling with an
end mill in many passes. In comparison to this,
the metal removal rate for the standard milling
cutter with indexable inserts that is used for uP-
Gear method is considerably higher. As a result,
machining rates much higher than those of the
previous values for end milling are achieved so
that the machine time is significantly reduced.
Standard milling cutters equipped with round
indexable inserts are the first choice through-
out when large material volumes have to be
machined. With this newly developed method
the technical and economical advantages can
also be incorporated for roughing tooth-spaces
in spiral bevel gears.
After opening up tooth spaces using round
Fig. 3: Milling cutter for finishing.
The same finishing cutter can be
used to machine both convex tooth
flanks and concave tooth flanks.
Single-edged mills that are fitted
with an increased number of stan-
dard indexable inserts can signifi-
cantly reduce machining time.
indexable inserts, tooth flanks are finished using
a new milling tool concept. The cutter types can
be classified as intermediate to a hollow-mill
and bell-type milling cutter. The variable setting
angle of the mill axis, combined with the slen-
der design of the milling cutter profile, allows
a wide range of flank angles and modules to
be machined. Both convex and concave tooth
flanks can be finished with the same tool hav-
ing inserts mounted on both sides. In the case
of the cutter being equipped with inserts only
on one side, in order to increase the number
of effective inserts—and, therefore, the feed
rate—considerable time savings are achieved.
The required additional tool change adds only a
marginal amount of time to the process.
Scratch-free machining of the tooth space
base and transitions to the tooth flanks is an
important quality feature of bevel gear manu-
facturing. This quality demand also applies for
the machining of the protuberance. The new
solution—a hollow mill with standard indexable
inserts for milling the protuberance—does not
just fulfill these requirements well. Another
advantage is that, when compared with the
previous end milling, the machining time is con-
siderably reduced.
Sustainable Solutions
When developing the new milling tools for
bevel gear machining, particular importance
APRIL 2011 51

Fig. 4: Protuberance milling. Good
surface finish and short machining
times are achieved with this dedicat-
ed milling cutter that is equipped with
CoroCut indexable inserts.
was placed on machine shop compatibil-
ity, stability, and efficiency. In each case the
diameter of the milling cutters and the number
of inserts was made to match each other to
achieve high levels of performance. The new
uP-Gear machining procedure and the advan-
tageous machine control has meant that the
special tools used before according to their
52 gearsolutions.com
special requirements can now be replaced by
universal milling tools with standard indexable
inserts.
Not only were the objectives set at the
start of the project reached, they were greatly
exceeded. After completing some batches of
bevel gears in module 15, the advantages of
the new procedure are clearly demonstrated
by the results:
• Soft machining can be completed in just
two setups, and the time required for this is
significantly reduced;
• Thanks to the lack of interference during
batch machining, the subsequent inspection
of soft-machined bevel gears in the measur-
ing machine revealed that the gear-wheel
quality is consistently high;
• The new procedure offers decisive advan-
tages for the machine operators. This is
because correction values are easy to use
for the operator and “setting cards” are no
longer required;
• Machining costs have been reduced con-
siderably through greater flexibility to lower
investment costs. The high-performance
standard tools combine a longer tool life
with increased productivity. Also, with suit-
able automation, production can be left to
run unmanned part of the time.
Encouraged by the success and the level
of motivation and input from the partners
involved in the project, the next step of opti-
mization is already under way. The area being
worked on now is hard-part machining, where
significant results have already been achieved
also using the new uP-Gear procedure. Other
projects such as implementing modified gear
tooth forms, machining bevel gears with axial
offsets, and the milling of crown gears are also
in the planning stages.
about The author:
Guenter Wermeister is with Sandvik
Coromant. Learn more by visiting
[www.sandvik.com].
 Product
SHOWCASE
New products, equipment, and resources

Solid Carbide Drills

from Seco Tools
Seco Tools has announced additions to its line of Feedmax™
solid carbide drills that avoid delamination upon entry or exit
when drilling in carbon fiber reinforced polymer (CFRP) materi-
als. The new –C1 geometry features a sharp optimized double
points, while the –C2 geometry is specifically designed to drill
stacked CFRP with an aluminum or titanium outer layer. To
combat the abrasive properties of CFRP the Feedmax –C1
and –C2 incorporate a polycrystalline diamond coating, which
also provides good dimensional tolerance. The new drills are
5xD with diameters ranging from 0.1260”-0.5”. All –C1 and
–C2 drills feature through-coolant holes. For more information
please visit [www.secotools.com].

New ZE15B Gear Grinding Machine from MHI

Mitsubishi Heavy Industries, Ltd. (MHI), has devel-
oped a new gear grinding machine, the ZE15B, suit-
able for volume production of gears up to 150 milli-
meters (mm) in diameter. The machine's high-speed
and high-accuracy machining capability will enable
further enhancement of productivity, coupled with
shorter time not used in machining operation, such
as time required for workpiece changes. The ZE15B
offers even greater volume production capability
than the company's ZE15A gear grinding machine,
which has earned a favorable reputation in the mar-
ket since its introduction in 2004. In response to
user demand for further space saving, installation
space has been reduced by 10 percent compared to
the ZE15A, to 3,980 millimeters (mm) in width and
4,000 mm in depth. Learn more at [www.mhi.co.jp/
en] or [www.mitsubishigearcenter.com].

APRIL 2011 53
Versatile Gaging System
from Renishaw
Equator™ is a radical new alternative to tra-
ditional dedicated gaging, filling a gap in the
market never before addressed. It is more
than just a new gaging system, it marks the
launch of Renishaw’s first gaging product line.
The patented low-cost design, unique in con-
struction and method of operation, is capable
of high-speed comparative gaging for inspec-
tion of high-volume manufactured parts. It
has been developed and proven on the shop
floor in collaboration with industry leading
companies in the automotive, aerospace, and
medical sectors. The result is a lightweight,
fast, and highly repeatable gage that opera-
tors can use with “push-button” simplicity.
Equator can switch between parts in seconds,
perfect for flexible manufacturing processes
or accepting parts from multiple machines.
Learn more by visiting [www.renishaw.com].

54 gearsolutions.com
Welding Apparel
from Lincoln Electric
Whether it’s welding in the field, in the
shop, or in a garage Lincoln’s new person-
al protection clothing line Red Line™ weld-
ing apparel offers the ideal gear for every
application. “Whether someone welds for
a living or is an occasional backyard
welder, safety is always at the forefront,
and that especially includes body and
eye protection,” says Jamy Bulan, product
manager. “They demand rugged, proven
clothing designed for their body type, appli-
cation, and environment. Red Line delivers
that protection.” The new product group
includes gloves, jackets, caps, and safety
glasses. Red Line personal protection
apparel is designed to work in tandem with
the comprehensive line of Lincoln Electric
VIKING™ auto-darkening welding helmets,
including the new 1840 and 2450 series.
For more information call (888) 355-3213
or visit [www.lincolnelectric.com].

APRIL 2011 55
 REGO-FIX’s swissQuick toolholding system provides a

Precision Toolholding
wide range of flexible models in various types (ER 8 - ER
25) and clamping ranges (0.5 mm - 13 mm). The swis-
sQuick system allows for faster tool changes and allows
Solutions from REGO-FIX pre-setting of tool assemblies offline to maximize pro-
duction time. swissQuick products are made from high
tensile strength case-hardened steel to reduce wear
and increase component life. REGO-FIX designs all of
its components to work together
interchangeably, resulting in the
flexibility to create solutions that
provide the best precision, balanc-
ing, and tool life across a broad
spectrum of applications. With
U.S. headquarters in Indianapolis,
Indiana, REGO-FIX is a world lead-
er in the manufacture of Swiss
precision tooling. For more infor-
mation call (800) REGO-FIX or visit
the company’s Web site at [www.
rego-fix.com].

56 gearsolutions.com
 GEARED FOR
SUCCESS
At AJAX Rolled Ring and Machine, our
dedicated team prides itself in providing
our customers with:

» Outstanding customer service

» Timely quotes
» Accurate documentation
» 2-week lead times
» On-time delivery
» Access to our extensive steel inventory
Gear up with AJAX.

ISCAR Expands HELIDO

Milling Line

A major expansion of the ISCAR HELIDO 845-13 mill family brings

the efficiency and economy of these popular tools to a wider size
and application range. Key additions to the cutter line include
extra-fine pitch cutters in the diameter range 2.0”-5.0” and coarse-
pitch models with coolant ports serving every pocket. New HP and
PL inserts are optimized to better handle austenitic cast iron, high C O N TAC T A N A J A X
temperature alloys, and stainless steels. Also added is a wiper R E P R E S E N TAT I V E TO DAY.
insert to improve finish using fine-pitch cutters of 5” and larger. www.ajaxring.com
Inserts are positive rake to reduce machining forces, and feature Toll Free: 800.727.6333
helical cutting edges to create a gentler entry and exit. The SUMO- Phone: 803.684.3133
TEC post coating has improved performance by 35 percent on aver-
age. For more information go to [www.iscar.com].

APRIL 2011 57
 New USB Input Tool from Mitutoyo
Mitutoyo America Corporation announces the availability of a new USB input device
that streamlines the interfacing of Mitutoyo Digimatic hand measurement tools with
PCs. The new USB Input Tool Direct: USB-ITN includes seven models, with each dedi-
cated to a specific type of cable plug/ connector pin configuration. The new design
negates the need for two cables, lowering overall costs by as much as 32 percent.
When connected to a PC’s USB port the tool is automatically recognized as an HID
(Human Interface Device) keyboard device—a standard Windows driver. No special
software is required. A USB keyboard signal converter translates Digimatic display
values to keyboard signals. More information is available at [www.mitutoyo.com].

58 gearsolutions.com
 < continued from page 18
al MPIF State-of-the-Industry Report. turnaround and unmatched value,” says bration and repair services for more than
Additional conference events include the Kathy Boyd, president, North America. 140,000 instrument models. It operates
Industry Recognition Luncheon and the “This facility places Tektronix Service in accordance with ISO 9001 and meets
PM Design Excellence Awards Luncheon. Solutions in a strong position to meet the requirements of ANSI/NCSL Z540-
The social highlight of the conference the demand and continue to enhance 1-1994 10CFR50 APP.B, 10CFR 21,
will be an evening at Alcatraz, including a our value proposition for both local and and NQA-1. Lab standard instruments
dinner cruise on San Francisco Bay. global clients.” are traceable to the National Institute
In addition to the comprehensive tech- The new lab provides single-source cali- of Standards and Technology (NIST).
nical program, the conference will include
continued on page 63 >
management-focused programs open to
MPIF-member companies: “PM And The
New Auto Industry”; an “Afterburner
Rapid Planning Workshop” following up
on the keynote presentation; a “PM
Technology Scan” focusing on the MIM
industry and on challenges to PM by
competitive technologies; and a ses-
sion featuring “The Growth Initiative,” a
new sales-oriented program designed for
manufacturers.
Technical sessions, poster presenta-
tions, and a slate of four special interest
programs will cover a range of subjects
such as metal injection molding, fatigue,
machinability, sintering, high-density pro-
cessing, low- and high-alloy steels, alu-
minum, composite materials, materials
for automotive applications, advances in
titanium, powder production, testing and
evaluation, compaction, and operational
advances. Other topics include tungsten,
refractory and hardmaterials, magnet
materials and applications, PM materi-
als for alternative energy, tribology, and
sinter hardening and leaner/economic
powders. For registration details and
the complete conference program visit
[www.mpif.org].

Tektronix Service Solutions

Opens California Facility
Tektronix Ser vice Solutions announc-
es the opening of its newest Next
Generation instrument services lab in
Santa Clara, California. The new facility
provides enhanced service options and
added flexibility for central California
companies that rely on test, measure-
ment, and control instrumentation for
day to day operations.
“The new Santa Clara facility is staffed
by the industry’s most experienced tech-
nicians with the broadest range of capa-
bilities. Coupled with leading-edge tech-
nology, clients receive high-quality, fast

APRIL 2011 59
 Manufacturing of magnectic work-
holding, fixtures and lifting devices
for multiple industries.

An OEM for New Large Capacity Gear Gasher/

Hobbers for Wind energy, mining, off-highway,
and Construction, as well as a supplier of
CNC Retrofit/Refurbished Gear Machinery.

If you haven’t seen RP lately,You havent Seen RP Machine!

 featuredSuppliers
Midwest Gear Corporation — REF #101
Phone: 330-425-4419 • Fax: 330-425-8600
Email: sales@mwgear.com
Website: www.mwgear.com
New England Gear — REF #102
Phone: 860-223-7778 • Fax #:860-223-7776
Email: jeff@newenglandgear.com
Website: www.newenglandgear.com
R. P. Machine Enterprises, Inc. — REF #103
Phone: 704-872-8888 • Fax #:704-872-5777
Email: sales@rpmachine.com
Website: www.rpmachine.com
Repair Parts, Inc. — REF #104
Phone: 815-968-4499 • Fax #:815-968-4694
Email: rpi@repair-parts-inc.com
Website: www.repair-parts-inc.com
Havlik International Machinery, Inc. — REF #105
Phone: 519-624-2100 • Fax: 519-624-6994
Email: havlik@bellnet.ca
Website: www.havlikinternational.com
GQ Machinery Inc.— REF #106
Phone: 516.867.4040 • Fax: 516.223.1195
Email: george@gqmachinery.com
Website: www.gqmachinery.com
GEAR ACCESSORIES, PARTS & TOOLING
FELLOWS Model #10-4/10-2, All Parts Available REF#102
Tilt Tables for 10-2/10-4, Qty 2 REF#102
FELLOWS Parts Available For All Models REF#103
BARBER-COLMAN – PARTS AVAILABLE FOR ALL MODELS REF#103
G&E – PARTS AVAILABLE FOR ALL MODELS REF#103
GEAR HOBBERS/CUTTERS CNC
LIEBHERR #LC-255 CNC, 6-Axis, 10” Dia, 10” Face, 4 DP, ‘87 REF#103
PFAUTER #PE-150, 6-Axis CNC, 6” Dia, 5 DP, 6” Face, Fanuc 18MI REF#103
SYKES #H160, 4-Axis CNC Hobber, 6” Dia, All the Features, ‘93 REF#103
G&E #60 S-2 CNC Gasher/Hobber REF#103
G&E #60SB-2C CNC, Gasher/Hobber REF#103
BARBER-COLMAN #16-36, 16” Dia, 4-Axis, 6 DP, 36” Face REF#103
LIEBHERR #LC-502 6-Axis CNC Gear Hobber, 20" Diam. Cap., Loading REF#103
LIEBHERR #L-652, 5-Axis 26” Dia,27” Face, 2 DP ‘09 REF#103
MUIR CNC Gear Hobber, 4-Axis, 118” Dia REF#103
LIEBHERR #L-252 3-Axis, 9.8” Dia, recontrolled 2008 REF#103
LIEBHERR #ET-1202 CNC - 70” Dia Internal, Single REF#103
LIEBHERR #ET-1802 CNC – 98” Dia Internal, 3-Axis REF#103
MITSUBISHI GD-20 CNC, 5-Axis, 8” Dia REF#103
G&E 120/188, CNC Gasher/Hobber, 188” Dia (5 Meter) REF#103
G&E #120GH, CNC, Gasher/Hobber, Twin Stanchion, 1/2 DP, 42” Face, ‘94 REF#103
PFAUTER P400H, 5-Axis, 18” Dia, 1 DP, Recontrolled ‘03 REF#103
G&E #160GH, CNC, Gasher/Hobber, New ‘07 REF#103
G&E #96GH, CNC, Gasher/Hobber, New ‘09 REF#103
HAMAI 60SP, CNC 4-Axis, 3.5" OD, 9" Face, 12 DP, New ‘89 REF#103
PFAUTER PE 300 AW CNC 6-Axis REF#103
GEAR HOBBERS/CUTTERS
PFAUTER P1251 Hobbers s/n 25-276 and 25-277 REF#102
PFAUTER (1) RS-00 s/n 17593 REF#102
BARBER COLEMAN (1) 16-36 multi cycle s/n 4404 REF#102
BARBER-COLMAN #16-16, Multi-Cycle, Dual Thread Worm and/or Single Thread
Worm REF#103
G&E #48H 48” Dia, 18” Face 2 DP, Universal REF#103
G&E #48H, 48” Dia, 35” Face, 3 DP, Gooseneck Attachment REF#103
LEES BRADNER HH-144 16” Dia, 144” REF#103
BARBER-COLMAN #6-16, 6 Multi-Cycle REF#103
G&E #36H Differential, Excellent Condition REF#103
BARBER-COLMAN #14-30, 14” Dia, 30” Face, 3.5DP REF#103
PFAUTER P-251 10” Dia, 9.6” Face, 4 DP REF#103
BARBER-COLMAN #14-15, 14” Dia, 15” Face, 1 to 4 Start Worm, Several
REF#103
BARBER-COLMAN #16-16, 16” Dia, 16” Face, 6DP REF#103
MACHINERY Contact Gear Solutions at
800-366-2185 to list your machinery.
BARBER-COLMAN #16-36, 24” Dia, C-Frame Style, 4 1/8” Bore REF#103
BARBER-COLMAN #16-56, 16” Dia, 56” Face, Differential REF#103
BARBER-COLMAN #22-15, 22” Dia, 14” Face, Differential REF#103
DAVID BROWN, 138” Dia, Face 60”REF#103
G&E #24H Universal Head, Infeed, Tailstock, Differential, ‘50’s REF#103
HAMAI #120, 4.8” Dia, 4” Face, 12 DP, ‘70 REF#103
LIEBHERR #L-402, 16” Cap, 2-Cut Cycle, Crowning, ‘77 REF#103
LIEBHERR #L-650, 26" Dia Cap, 14.5" Face, 2.5 DP, New ‘70’s REF#103
MODUL #ZFZW 800, 29.8” Dia, 16.25” Face, 2.5 DP Crowing, 2-Cut REF#103
BARBER-COLMAN #1600-36, 16" Dia., 39.5" Face, 6 DP REF#103
CHONG QIN #Y3180H, 31.5 Dia., 15" Face, 3 DP REF#103
FELLOWS FH-200 Max Diam 7.87" Max Dia Pitch 5.08" REF#103
G&E #16H Gear Hobber, 16"Dia REF#103
BARBER-COLMAN #3 (6-10), Single & Triple Tread Worm HS REF#103
BARBER-COLMAN #6-10, 6” Dia, 10” Face, 16 DP REF#103
KOEPFER #140 , 2.75” DIa, 4” Face REF#103
KOEPFER #153B, 5.6” Dia, 5.9” Face REF#103
LANSING #GH-50, 50” Dia, 17.75” Face, 2 DP REF#103
LIEBHERR #L-252, 9.8” Dia, 7.9” Face, 4.2 DP REF#103
MIKRON #79 1.5 Dia, 26 DP REF#103
BARBER-COLMAN TYPE T REF#103
IUG –Craiova FD-3600 REF#103
LIEBHERR #L-401, 15.7” Dia 11” Face, 3DP REF#103
G&E #36HS 36”Dia, 14” Face 3 DP REF#103
PFAUTER #P-3000, 120” Dia, Single Index REF#103
SCHIESS RFW-10-S 55” Dia REF#103
SHIBURA HHC-250A Single Index REF#103
OVERTON #HD-400, 15.7” Dia, 12” Face, 3 DP, New ‘88 REF#103
SCHIESS 1 RF-10, Dia 60” 150” L, .50 DP REF#103
G&E #40TWG, 48” Dia, 18” Face, 3 DP REF#103
G&E #60S, 72” Dia, 14” Face, 1.25 DP REF#103
G&E #72H, 72” Dia, 24” Face, 1 DP REF#103
G&E #96H, 104” Dia, .50 Face, 1.25 DP REF#103
PFAUTER #P-630, 25” Dia REF#103 w/Diff REF#104
PFAUTER #2500, 100” Dia REF#103
TOS FO-16, Max Cut w/support 90” REF#103
PFAUTER P250 10” Dia REF#103
GE Hobber 200” Dia, 55” Face REF#103
GE/Fitchburg Hobber 32” Dia, 72” Face 1.25DP REF#103
JF Reinecker 40” Dia 35” Face REF#103
LIEBHERR L-160-R 6.5” Dia REF#103
MIKRON #102.04 , 4’ Dia, 5” Face REF#103
NIHON-Kikai NDH-1200 50” Dia REF#103
PFAUTER P-900 36” Dia REF#103
SCHIESS RF 40/60S 240” Dia 100” Face REF#103
BARBER-COLMAN #25-15 25” Dia, 15” Face, 2.5 DP REF#103
CRAVEN Horizontal , 18” Dia and 100” Length REF#103
KOEPFER #173B, .6.1” Dia, 7” Face REF#103
PFAUTER #P-630R, 25" Max. Spur Dia, 12" Max Rotor Dia. 12" REF#103
BARBER-COLMAN 2 1/2 -4, S/N 119, ’62 Hi-Production Spur Gear REF#104
BARBER-COLMAN 6-10 SYKES, Triple Thrd w/Lever Operated Collet Assy REF#104
BARBER-COLMAN 6-10 B&C Ltd, S/N 8079, Triple Thrd REF#104
BARBER-COLMAN 6-10, S/N 4626, ’57 Triple Thrd 3” Hob Slide REF#104
BARBER-COLMAN 6-10, S/N 4659R, ’56 Triple Thrd Adj Ctr Assy REF#104
BARBER-COLMAN 6-10, S/N 4665, ’57 Fine Pitch Prec Triple Thrd REF#104
BARBER-COLMAN 6-10, S/N 4701, ’58 Triple Thrd w/Power Down Feed REF#104
BARBER-COLMAN 6-10 M/C, S/N 4755, ’59 Triple Thrd w/MC Conversion REF#104
BARBER-COLMAN 6-10 Multicycle, S/N 4778R87, ’60 (’87 Rebuild), Sgl Thrd Hi-Spd
REF#104
BARBER-COLMAN 6-10 M/C, S/N 4913, ’63 Triple Thrd w/90 Deg Hob Slide
REF#104
BARBER-COLMAN 6-10 Multicycle, S/N 5055, ’66 Triple Thrd, 800 RPM REF#104
BARBER-COLMAN 6-10, S/N 5141, ’67 Triple Thrd w/Prec Hob Shift REF#104
BARBER-COLMAN 6-10 Multicycle, S/N 5148, ’68 Triple Thrd, 800 RPM REF#104
BARBER-COLMAN 6-10 Multicycle, S/N 5259, ’75 Triple Thrd w/Auto
Hob Shift REF#104
BARBER-COLMAN 6-10, S/N 5353, ’77 Triple Thrd w/3” Hob Slide,
800 RPM REF#104
BARBER-COLMAN 6-10, S/N 5394, ’81 Fine Pitch Triple Thrd w/Dwell
& Hob Rev REF#104
BARBER-COLMAN 6-16 M/C, S/N 5238, ’70 Triple Thrd, Recon ‘02 REF#104
BARBER-COLMAN 6-10, S/N 5407, ’82 Auto w/PLC Control REF#104
BARBER-COLMAN DHM, S/N 105, ’42 Double Thrd REF#104
BARBER-COLMAN 14-15, S/N 635R, ’53 Dbl Thrd, Fact Reb REF#104
BARBER-COLMAN 14-15, S/N 745, ’55 Dbl Thrd w/Dwell REF#104
BARBER-COLMAN 14-15 Dual Fd, S/N 938, ’62 Dbl Thrd, Comp Reco REF#104
BARBER-COLMAN 14-15, S/N 1055, ’65 Dbl Thrd w/New Hyd Sys REF#104
BARBER-COLMAN 14-15, S/N 1131, ’66 Dbl Thrd w/Hyd Tailctr REF#104
BARBER-COLMAN 14-15 Dual Fd, S/N 1261, ’67 Dbl Thrd w/Hyd Live Ctr
REF#104
BARBER-COLMAN 14-15 Dbl Cut, S/N 1278, ’68 Dbl Thrd w/4-1/8” Bore REF#104
BARBER-COLMAN 14-30 Dual Fd, S/N 1371, ’71 4-Thrd w/Sizing Cycle REF#104
BARBER-COLMAN 22-15, S/N 923, ’62 Dbl Thrd, Dbl Cut REF#104
BARBER-COLMAN 16-11, S/N 184, ’50 Dbl Thrd w/Vert DRO REF#104
BARBER-COLMAN AHM, S/N 1896, ’42 Sgl Thrd w/3 Jaw Chuck REF#104
BARBER-COLMAN 16-16, S/N 2745, ’51 Sgl Thrd w/90 Deg Hd REF#104
BARBER-COLMAN 16-16, S/N 3171, ’53 Dbl Thrd, Spanish Nameplates REF#104
BARBER-COLMAN 16-16, S/N 3580, ’59 Dbl Thrd w/Diff & Auto Hobshift
REF#104
BARBER-COLMAN 16-16 Multicycle, S/N 3641, ’60 Dbl Thrd w/Diff REF#104
BARBER-COLMAN 16-16, S/N 3660, ’57 Sgl Thrd REF#104
BARBER-COLMAN 16-16, S/N 4136, Dbl Thrd, “C” Style End Brace w/Diff
REF#104
BARBER-COLMAN 16-16 Multicycle, S/N 4170, Dbl Thrd w/Jump Cut Cycle “
C” Style REF#104
BARBER-COLMAN 16-16, S/N 4473, ’73 4-Thrd w/Workclamp Cyl “C” Style
REF#104
BARBER-COLMAN 16-16 Multicycle, S/N 4520, ’75 Dbl Thrd w/Gooseneck Slide
REF#104
BARBER-COLMAN 16-16 Multicycle, S/N 4631, ’79 “C” Style End Brace, 4W Adj
Ctr REF#104
BARBER-COLMAN AHM (36”), S/N 1152, ’42 Dbl Thrd REF#104
BARBER-COLMAN 16-36, S/N 4090, ’66 Dbl Thrd, “C” Style End Brace REF#104
BARBER-COLMAN 16-36 Multicycle, S/N 4232, ’68 Dbl Thrd “C” Style End Brace
BARBER-COLMAN 16-56, S/N 3136R84, ’53 (Reb ’84), Dbl Thrd REF#104
BARBER-COLMAN 10-20, S/N 6700045890, ’76 Dbl Thrd w/2 Cut Cycle REF#104
TOS OFA Series Conventional Gear Hobbers, 12” & 40” Dia REF#105
TOS OHA Series Conventional Gear Shapers, 12” & 40” Dia REF#105
GEAR PINION HOBBERS & SPLINE MILLERS
HURTH #KF-32A 15” Dia, 59” Face, ‘67 REF#103
GE/Fitchuburg Pinion Hob 32” Dia, 72” Face REF#103
MICHIGAN Tool #3237 REF#103
SCHIESS 1 RF-10, 60” Dia REF#103
WANDERER GF 345 CNC Hobbing /Milling Machine 4-Axis 24" Swing x 240”
Length REF#103
FITCHBURG Pinion Hobber 42” Dia, 72” Dia REF#103
CRAVEN Horizontal, 18” Dia and 100” Length REF#103
GEAR HOB & CUTTER SHARPENERS (incl CNC)
ARTER #A-12, 12” Rotary Surface Grinder for Sharpening Sharper Cutters
REF#103
BARBER-COLMAN #6-5, 6" Dia, 5" Length, Manual Dresser, ‘57 REF#103
BARBER-COLMAN 10-12, 10" Dia, 12" Length, Spark Out REF#103
FELLOWS #6SB, Helical Cutter Sharpener, 6” Dia, up to 50 Degrees REF#103
KAPP #AS-305GT, 1 DP, 28" Grind Length, 10" Diam., Str. & Spiral REF#103
KAPP #AS204GT, 10” Dia, Wet Grinding, CBN Wheels, ‘82 REF#103
BARBER-COLMAN #3 HS, Hob Sharpener, 4" Max. OD., 4" REF#103
BARBER-COLMAN #4-4HRS, Hob Sharpener, 4" Max. OD. 4" REF#103
REDRING MODEL #SGH "PREIFORM" SHAVE CUTTER GRINDER/SHARPENER
REF#103
STAR 6X8 HOB SHARPENER PRECISION GEAR & SPLINE HOBBER REF#103
BARBER-COLMAN 2-2 1/2 , 2.5” Dia REF#103
KAPP #AST-305B, 27.5” Dia, REF#103
KAPP AS-410B REF#103
GLEASON #12 Sharpener, 3-18” Cone REF#103
BARBER-COLMAN 2 1/2-2, S/N 16, ’66 Wet w/Auto Feed REF#104
BARBER-COLMAN 6-5, S/N 110R, ’55 Wet w/Auto Dress & Sparkout REF#104
BARBER-COLMAN 6-5, S/N 396, ’66 Wet w/Auto Dress & Sparkout REF#104
APRIL 2011 61
BARBER-COLMAN 6-5, S/N 433, ’69 Wet w/Auto Dress & Sparkout REF#104
BARBER-COLMAN 10-12, S/N 643R83, Wet w/Auto Dress, PC Control, Fact
Reb ‘83 REF#104
TOS OHA Series CNC Gear Shapers, 12” & 40” Diameter REF#105
TOS OFA Series CNC Gear Hobbers, 12” & 40” Diameter REF#105
GEAR SHAPERS CNC
36” Shapers, 14” Throat Risers, 53” of Swing, Qty 3 REF#102
FELLOWS #10-4/10-2, Qty 150 REF#102
HYDROSTROKE #50-8, Qty 2 REF#102
HYDROSTROKE #20-8, Qty 5 REF#102
HYDROSTROKE #FS630-125, Qty 1 REF#102
HYDROSTROKE #FS400-90, Qty 2 REF#102
FELLOWS #20-4, Qty 6 REF#102
FELLOWS #48-8Z, Qty 1 REF#102
FELLOWS #FS-180, 3-5 Axis, 7” Dia, 1.25” Face., 6 DP, New ‘88 REF#103
LIEBHERR #WS-1, 4-Axis CNC, 8" OD, 2" Stroke, Fanuc 18MI REF#103
LORENZ # LS-180, 4-Axis CNC, 11” OD, 2” Stroke, 5 DP REF#103
LORENZ #LS-304 CNC Gear Shaper 5-Axis Heckler & Koch Control REF#103
LORENZ #LS-156 CNC Gear Shaper Dia 6” REF#103
FELLOWS FS400-125, 16” Dia, 3.5 DP 5” Face REF#103
SCHIESS RS-20 S, 12” Stroke, 118” Dia REF#103
FELLOWS #10-4 3-Axis (A/B), 10" Dia, 4" Face, 4 DP New .’09 REF#103
RP-GS 800 CNC, 4-Axis, Max Dia 31.5”, Face 9”, 2.5 DP REF#103
RP-GS 400 CNC, 6-Axis, Max Dia 15” Face 4”, 3 DP REF#103
STANKO /RPM #48-8 Gear Shaper CNC, Fanuc 18 REF#103
FELLOWS #10-4 2-Axis, 10” Dia 4” Face REF#103
FELLOWS #20-4 3-Axis 10” Dia, 4” Face REF#103
FELLOWS FS400-90 Hydro-stroke Gear Shaper CNC Nominal Pitch 15.7"
REF#103
RP-GS 1500 CNC, 4-Axis, Max Dia 49.2”, Face 12”, 2 DP REF#103
GEAR SHAPERS
FELLOWS #10-2, (10” Dia), 2” Face REF#102
FELLOWS #10-4, (10” Dia), 4” Face REF#102
FELLOWS (200) 10-4 / 10-2 Shapers REF#102
FELLOWS (1) 50-8 Hydrostroke Shaper s/n 36607 w/
6 axis 16iMB Fanuc (2009) REF#102
FELLOWS (1) 20-8 Hydrostroke Shaper s/n 35932 w/
6 axis 16iMB Fanuc (2009 REF#102
FELLOWS (1) #7 125A Face Gear Machine REF#102
FELLOWS (2) #3 Face Gear Machine REF#102
(1) 4ags with adjustable Helical Guide s/n 30634 REF#102
(1) #7 125A adjustable Helical Guide REF#102
FELLOWS (1) FS630-200 Hydrostroke Shaper s/n 36943 w/
6 axis 16iMB Fanuc (2009) REF#102
FELLOWS (3) Tilt Table 10-4 / 10-2 w/ 4 axis 21i Fanuc
Controller (2009) REF#102
FELLOWS (2) Swing-away center support for 10-2 / 10-4 REF#102
FELLOWS (1) FS630-170 Hydrostroke Shaper s/n 36732 w/
6 axis 16iMB Fanuc (2009) REF#102
FELLOWS (2) FS400-170 Hydrostroke Shaper w/
6 axis 16iMB Fanuc (2009) REF#102
FELLOWS (4) FS400-125 Hydrostroke Shaper w/ 6
axis 16iMB Fanuc (2009) REF#102
FELLOWS (1) 20-4 Shaper s/n 35687 w/ 4 axis
21i Fanuc Controller (2009) REF#102
FELLOWS (1) 48-8Z Shaper w/ 14” throated riser (53” of swing) REF#102
FELLOWS (1) Horizontal Z Shaper s/n 21261 REF#102
FELLOWS (1) 4-B Steering Sector Gear Shaper w/ 18iMB
4 axis Fanuc controller s/n 34326 REF#102
FELLOWS (1) 36-10 Gear Shaper REF#102
FELLOWS (1) 10x6 Horizontal Z Shaper REF#102
FELLOWS (1) 36-6 Gear Shaper w/ 13” riser s/n 27364 REF#102
FELLOWS (1) 10-4 Shaper w/ 3” riser w/ 4 axis 21i
Fanuc Controller (2009) REF#102
All Parts for 10-4/10-2 Fellows Gear Shapers REF#102
FELLOWS #36-8, 36” Dia, 8” Face REF#103
FELLOWS #100-8 100” Dia, 8” Face REF#103
FELLOWS #612A, 615A, #645A REF#103
FELLOWS #10-4, 10” Dia, 4” Face, 4 DP REF#103
FELLOWS #4A Versa, 10” Dia, 3” Face, 4 DP, New ‘70’s REF#103
FELLOWS #10-2, 10” Dia, 4” Face, 4 DP REF#103
FELLOWS #20-4, 20” Dia, 4” Face, 4 DP, ‘70’s REF#103
MAAG #SH-100/140, 57” Dia., 12.6” Face, 2 DP, Internal Attachment
REF#103
FELLOWS #3-1,/3GS, 3” Max Dia, 1” Face, Pinion Supp, High Precision
REF#103
FELLOWS #48-6 INTERNAL GEAR SHAPER ONLY,0-72"OD,6" Face REF#103
LORENZ #SJV00, 7” Dia, 2” Face, ‘50’s REF#103
MAAG #SH-100K 47”/12.6”/1.7 ‘60’s Internal Attachment REF#103
MAAG #SH-150, 57" Dia.12.6" Face REF#103
PFAUTER #SH-180 Shobber 7" capacity hobbing, 9.45" cap REF#103
FELLOWS #36-6 Max Dia 36” 6” Face, 3 DP REF#103
62 gearsolutions.com
FELLOWS #HORZ Z SHAPER, 10 x 6 Dia 27.6 Face 8.5” REF#103
MAAG #SH-75C, 30”/8”/2.5”/’52 REF#103
MAAG #SH-600, 235” Dia 36”, 1DP REF#103
FELLOWS #4GS & 4AGS, 6” Dia, 2” Face, 4DP, ’68, Ref.# Several REF#103
TOS OH-6, Dia 19.7” REF#103
FELLOWS #624A, 18” Max Dia, 5” Face REF#103
FELLOWS #7, #7A, #715,# 75A, #715, #725A, 7” Dia, 0-12” Risers,
Several Avail REF#103
MAAG #SH-180-300 , Max Dia 118”/ 16.9” Face REF#103
MAAG #SH-350/500, Max Dia 197” REF#103
MICHIGAN #18106 SHEAR-SPEED GEAR SHAPER,14" Dia, 6"Face REF#103
FELLOWS Model Z Shaper, 5" Stroke, ‘50’s REF#103
STAEHELY SHS-605, Gear Shaper REF#103
FELLOWS #6, #6A, #61S, From 18”-35” Dia, 0-12” Risers REF#103
FELLOWS #8AGS Vertical Gear Shaper, 8” Dia, 2” Face, 6-7 DP REF#103
TOS OHA50 CNC 5 20” Dia 5” Face REF#105
Fellows 36-6 Shaper (2) 12.5" Risers 6" Stroke Mint YR 1969 id 3616
REF#106
GEAR DEBURRING/CHAMFERING/POINTING
CROSS #50 Gear Tooth Chamferer, 18” Dia, Single Spindle REF#103
CROSS #75 Gear Tooth Chamferer, 10” Dia, 10” Face, ‘52 REF#103
REDIN #18, 28” Dia, 2, 3, 4 Spindle, Deburrer/Chamfer, PLC’s, Tilt Table
REF#103
REDIN #20D, 20” Dia, Twin Spindle, Deburrer/Chamfer REF#103
SAMPUTENSILI #SCT-3, Chamf/Deburrer, 14” Dia, 5” Face, ‘82 REF#103
SAMPUTENSILI #SM2TA Gear Chamfering Mach, 10” Max Dia, (3) New ‘96
REF#103
REDIN #24 CNC Dia 4” Setup Gear Deburring REF#103
CROSS #60 Gear Tooth Chamferer, 10” Dia, Single Spindle REF#103
FELLOWS #100-180/60 CNC Max Dia 180”, Single Spindle REF#103
CIMTEC #50 Finisher REF#103
RPM #GC-500 CNC 20” Dia, Single Spindle REF#103
CROSS #54 Gear Deburrer, 30” Dia, 18” Face REF#103
RED RING #24 Twin Spindle Dia 4” REF#103
CROSS #55 Gear Deburrer, 18” Dia, 1.5 Spindle REF#103
GLEASON GTR-250 VG CNC 5-Axis REF#103
GRATOMAT #300L REF#103
GEAR Honers
Fassler #K-400 CNC Hone 16" Dia REF#103
Fassler K-400A CNC Hone 16” Dia REF#103
Kapp #CX120 Coroning 4.7” Dia REF#103
Red Ring GHD-12, 12” Dia, 5.5 Stroke REF#103
Red Ring GHG, 12” Dia, 5.5 Stroke REF#103
Kapp #VAC65 Coroning 10” Dia REF#103
GEAR SHAVERS
Red Ring #GCX-24" Shaver, 24” Dia, 33” Stroke REF#103
Red Ring #GCU-12, 12” Dia, 5” Stroke REF#103 FELLOWS (1) 20 M Roller Checker REF#102
Red Ring #GCU-8 Shaver. 8” Dia REF#103
Red Ring #GCY-12, 12” Dia, 5” Stroke REF#103 FELLOWS (1) #8 Micaodex s/n 36279 REF#102
Red Ring GCI 24, 12.75” Dia, 5” Stroke REF#103
Nachi Raso CNC Shaver, 3-Axis REF#103
Michigan #873-24A, 24” Dia, 15” Face, 2 DP REF#103
GEAR GENERATORS, STRAIGHT BEVEL
GLEASON #37 Str. Bevel Planer, 6” Dia REF#103
GLEASON #54 Str, Bevel Planer, 60” Dia REF#103
GLEASON #496 Straight.& Spiral. 7.5” Dia REF#103
GLEASON 14, Coniflex Straight Bevel REF#103
GLEASON 24A Straight Bevel REF#103
GLEASON 725-Revacycle, 6” Dia REF#103
GLEASON 726-Revacycle, 5” Dia REF#103
GLEASON 2A, 16” Cone REF#103
GLEASON #116, 9” Cone, 2.75 Face REF#103
GLEASON #104 w/Helical Motion, Coniflex, Straight Bevel REF#103
GEAR GENERATORS, SPIRAL BEVEL (HYPOID)
GLEASON #645 Hypoid Generators REF#103
GEAR GRINDERS CNC
HOGLUND, Model #264, CNC Internal Gear Grinder REF#103
KAPP #VAS-482 CNC GEAR GRINDER, 11.8" SWING DIA REF#103
GLEASON Phoenix 200G Hypoid Grinder CNC REF#103
REISHAUER RZ-801 CNC, 31.4” Dia REF#103
NILES ZSTZ 06-800 CNC, 31.5” Dia, 11” Face REF#103
NILES ZSTZ 08-800 CNC, 32” Dia, 11” Face REF#103
RED RING #SF-500 CNC Int/Ext, 26” Dia, REF#103
GLEASON/TAG – 400 CNC, 16” Dia REF#103
HOLFER PROMAT 200 , 7.87” Dia CNC Gear Grinder REF#103
GEAR GRINDERS
#27, #137, and #463 Gleason Hypoid Spiral Bevel gear grinder
generating Cams (2 full sets) REF#102
Springfield Vertical Grinder, 62" Table, #62AR/2CS, 3.5A Rail Type, 70" Swing
REF#102
REISHAUER ZA, Gear Grinder, 13" Dia, 6" Face, Strait & Helix REF#103
RED RING #SGJ-18, 18” Dia., 9” Face, Internal Attachment, New ‘78
REF#103
DETROIT Gear Grinder #GGI-16x3A, Internal Gear Grinding, 16" OD REF#103
MAAG SD-32-X REF#103
GLEASON #463, 15” Dia REF#103
HOFLER BHS H1603-2000, 78.7” Dia REF#103
NILES ZSZT-3500, 139” Dia REF#103
KAPP VAS #331, Gear Grinder REF#103
NILES ZSTZ-1250/5000 49.2Dia REF#103
GEAR RACK MILLERS/SHAPERS
MIKRON #134 Rack Shaper, 17.4" Length, 1.1" Width, 16.9 DP REF#103
SYKES VR-72 Vert Rack Shaper, 72" Cut Length, 4DP, 4" Stroke, ‘80
REF#103
SYKES VR-60 Vert Rack Shaper, 60” Cut Length, 4DP, Stroke 4” REF#103
GEAR THREAD & WORM, MILLERS/GRINDERS
LEES BRADNER #HT 12x54, Dia 12” /54” REF#103
MOREY-SHIELDS THREAD MILLER, Dia 12” REF#103
BARBER-COLMAN #10-40, 10" Dia., 40" Length, 4 DP REF#103
EXCELLO #31L, External Thread Grinder, 5" OD, 20" Grind Length REF#103
EXCELLO #33 Thread Grinder 6” Dia 18” Length REF#103
EXCELLO #35 and #35L Thread Grinder, 84" Between Centers REF#103
EXCELLO #39 Int. Thread Grinder, 9.5" Max Dia., 10" Max. Swing REF#103
HURTH #KF-33A Multi-Purpose Auto-Milling Machine 88” REF#103
LEES BRADNER #HT12x102, Extra Large Capacity REF#103
J&L AUTOMATIC THREAD GRINDER, 6" X 36", ‘38 REF#103
LEES BRADNER #HT 12"x 144" Thread Mill, 12" Dia, REF#103
WALDRICH COBURG WHIRLING, 3” Dia, 118” Length REF#103
LEES BRADNER # LT 8” x 24” 8” Dia REF#103
HOLROYD 5A 24.8 “ Dia REF#103
HECKERT WMW #ZFWVG REF#103
LEES BRADBER WORM MILLER REF#103
GEAR TESTERS/CHECKERS (incl CNC)
FELLOWS (1) RL-600 Roll Tester s/n 35814 REF#102
FELLOWS (1) 24H Lead Checker s/n 32289 REF#102
GLEASON (1) #14 Tester s/n 31907 REF#102
GLEASON (1) #6 Tester s/n 19316 REF#102
FELLOWS (1) 20 M w/ 30” Swing Roller Checker REF#102
David Brown #24 Worm Tester REF#103
Fellows 12H Gear Tester REF#103
Fellows #12M Gear Tester REF#103
Fellows 20M Gear Tester REF#103
Felows #24 Involute Measuring Instrument REF#103
Gleason #4, #6, #13 and #17 Testers REF#103
Hofler EMZ-2602 Int/Ext Gear Tester 102” REF#103
Klingelnberg #PFSU-1200 Gear Tester REF#103
Klingelnberg #PFSU-1600 Gear Tester-2001 REF#103
Klingelnberg PWF-250 Tester REF#103
Kapp Hob Checker WM 410 REF#103
Maag #ES-430 Gear Tester REF#103
Maag #SP-130 Lead and Involute Tester REF#103
National Broach Gear Tester GSJ-12 REF#103
Oerlikon #ST2-004 Soft Tester REF#103
Maag #SP-60- Electronic Tester REF#103
Parkson #42N Worm Gear Tester REF#103
Fellows #24H Tester REF#103
Gleason #104 Tester REF#103
Vinco Dividing Head Optical Inspection REF#103
MISCELLANEOUS
WARNER & SWAYSEY #4A M-3580 Turret Lathe, 28 1/4 Swing, 80” Centers, 12”
Spindle Hole 50/25 Motors, 480/3 Phase, Year 1965 REF#101
Springfield Vertical Grinder, 62" Table, #62AR/2CS, 3.5A Rail Type, 70" Swing REF#102
GLEASON #529 Quench, 16" Diameter REF#103
VERTICAL TURNING LATHES AND MORE - Please Check Our
Website To View Our Entire Inventory REF#103
TOS SU & SUS Series Conv Lathes REF#105
TOS SUA Series CNC Flat-Bed Lathes REF#105
< continued from page 59
The center provides clients access to
Tektronix Service Solutions’ unparalleled
capabilities, including:
Single - source provider—Tek tronix
Service Solutions can manage a custom-
er’s entire test, measurement and control
instrumentation program. Direct service
capabilities reduce purchase orders and
lower overall costs for customers.
Global network/local service—An exten-
sive global network ensures local ser-
vice, technical expertise, scalability, and
flexible service packages backed by 80
worldwide locations and more than 1,000
experienced associates providing custom-
ers a significant reduction in equipment
downtime.
Flexible solutions—Tektronix Service
Solutions offers clients the ability to cus-
tom-tailor their service requirements by
offering multiple package options, com-
petitive pricing and consulting services
designed to provide the best business
value for a customer’s unique needs.
Tektronix Service Solutions, a TEKTRONIX
company, is the world's leading single-
source provider of instrument calibration,
repair and related services, which extends
to more than 140,000 products from
9,000-plus manufacturers. Go online to
[service-solutions.tektronix.com].
Good News at FMA Annual
Conferences
Two spirited keynote speeches that
offered bullish perspectives on the future
of U.S. manufacturing—with specific
caveats—highlighted The FABRICATOR®’s
Leadership Summit, 6th Annual Metal
Matters, and FMA’s 15th Annual Toll
Processing Conference, held in early
March in Orlando.
Emily DeRocco, president of The
Manufacturing Institute and the new
National Center for the American
Workforce, and Dan DiMicco, chairman,
president, and CEO of Nucor Corporation,
the leading U.S. steel producer and the
world’s largest recycler, each told the
gathering of more than 200 executives
at the premiere conferences for the pro-
cessing and fabricating industry that the
manufacturing sector can again be a
global leader.
DeRocco outlined how even in today’s
tough economic climate, U.S. manufac-
turing represents the world’s eighth larg-
est economy, pays premium compensa-
tion when compared to non-manufac-
turing jobs, offers the strongest multi-
plier effect, and outpaces global rivals in
research and development. However, she
noted a recent survey revealed 32 per-
cent of companies reported “moderate
to serious skills shortages in the hiring
pool” and that “technological advances
in modern manufacturing require more
advanced skill sets. “Major deficits in
our education system hamper U.S. com-
petitiveness on the world stage,” she
said. “Our global competitors continue to
surpass our education system in produc-
ing a high-volume, high-quality technical
workforce.”
DiMicco painted a bleaker picture of
the sector’s current status, citing the
large number of manufacturing jobs lost
since its high point in 1998 and report-
ing the current level is the lowest since
1941. “How did we get here?,” he asked.
“A massive failure of trade policies. And,
we bought into a failed economic model
that a ser vice-based economy could
replace a manufacturing-based econo-
my.” He asserted manufacturing can lead
the way to create more jobs and real
wealth via several ways. One is to achieve
energy independence by “developing all
domestic energy resources—traditional
and renewable. This will create jobs by
building an energy infrastructure and driv-
ing R&D in the energy sector.”
The three-day events were produced
by The Fabricators & Manufacturers
Association, International (FMA) and The
Tube & Pipe Association, International
(TPA).
The 2012 summit and conference will
take place Feb. 29 through March 2 at
the Talking Stick Resort in Scottsdale,
Arizona. Learn more by calling (888)
394-4362 or going to [www.fmanet.org/
calendar].
Promotion at Emerson Bearing
Emerson Bearing—a Boston-based bear-
ing company catering to OEM (Original
Equipment Manufacturers) and MRO
(Maintenance, Repair and Operations)
markets nationally and internationally—
has recently promoted Bob Piracini to
marketing specialist.
As marketing specialist he will lead the
new machine tools division and assist
clients in determining which bearing tech-
nologies would be most suitable by tak-
ing into consideration the specifications,
recommendations, maintenance strate-
gies, fatigue life, and wear resistance of
the bearing in relation to the application.
His clients are typically spindle repair
and machinery rebuilds. They range from
regional and national “mom and pop”
operations to large companies. Piracini
will continue to travel throughout New
England several times a year visiting com-
panies and promoting Emerson Bearing.
Piracini previously held the position of
sales representative at Emerson Bearing
for 14 years. He holds a bachelor’s degree
from Suffolk University and is a resident
of Somerville, Massachusetts. To reach
him call (866) 995-8764 or e-mail bpira-
cini@emersonbearing.com. Go online to
[www.emersonbearing.com.].
New Direction for
Chevalier in 2011
Chevalier Machinery has a new sales direc-
tion for 2011, focusing on selling “Large
Capacity and Heavy Duty Machining,” and
there are some specific models being
focused on for both for their grinding and
chip cutting divisions. The FVM-3016 is
the top of the line DCL type double col-
umn vertical machining center offered,
and it features heavy duty precision and
APRIL 2011 63
state of the art spindles that will make
any job easier to complete. And the
new QP vertical machining centers will
lead the way in their milling lineup. The
FVM-DCL series is the company’s entry
level double columns bridge machine. It
provides large capacity: table size starts
from 126” x 57”. Great cutting capabil-
ity: 2-speed gearbox spindle that gener-
64 gearsolutions.com
ates maximum 451 ft-lbs torque. And the
new QP series machining centers is the
C type machining center with heavy duty
boxways construction plus 50 taper gear
spindle. It is perfect for cutting tough
material and the machining capacity is
up to 88” x 40”.
The Big Bore FBL-500 series lathes
and F VL-1600VTC vertical turning center
are the company’s strongest sellers in
its turning line-up. These high precision,
multi-tasking vertical machining centers
features a very rigid machine structure
which reduces the cutting induced vibra-
tion associated with machining hard
metals like titanium. They have fully sup-
ported, wide box ways on the Y axis for
handling heavy loads. And on the turning
side, to satisfy the booming of energy
industry, Chevalier produces the new
FBL-500 series horizontal lathe and FVL
series vertical lathe. The FBL-500 lathe
has a large spindle bore, diameter is up
to 12.5” and turning length is 160”. The
FVL series vertical lathe can fit in maxi-
mum 98” diameter part with weight up to
26,400 lbs.  To eliminate time consume
of setup, both models all provide live
tooling, C axis, and even Y axis machin-
ing capability.
The FSG-40/50/60 Series large dou-
ble column with fixed beam CNC Graphic
Conversational Surface Grinders are
designed for shops demanding speed,
rigidity and a very large grinding area. 
This series of grinding machines is per-
fect for grinding large work pieces and are
what the biggest machine shops will be
looking for.  Chevalier will also be focus-
ing on more competitive pricing which will
make their machines often cheaper than
the competition. For more information go
to [www.chevalierusa.com].
SME Announces Green
Manufacturing Program
The Society of Manufacturing Engineers
(SME) has par tnered with Purdue
University Technical Assistance Program
(TAP) on a Green Manufacturing Specialist
Certificate Program. Purdue TAP has
developed an extensive training program
and SME has developed the outcome
assessment. Each program component
was built to work together or to use
independently, creating a highly flexible
workforce development solution.
Manufacturers are seeing the value
of applying green practices to their pro-
cesses. They are discovering that it’s
not only good for the environment, but
practicing sustainability is also good for
the bottom line. And to be successful in
reducing waste, manufacturing employ-
 MARKET
PLACE
Manufacturing excellence
through quality, integration, materials,
maintenance, education, and speed.

We Manufacture
Broaches & Related
Tooling for
any Broach Machine
Sharpening or Reconditioning
Also Production Broaching
We Weld Broken & Chipped Broaches

Broach House
Mfg., Inc.™
We Have Used Broaches In Stock
11383 Route 166 • Marion, Il 62959
618-993-3530 • Fax:618-997-9158
e-mail: broachhouse@yahoo.com

Apollo Broach, Inc.

www.apollobroach.com

Services: Round Broach:

• Broach Design • Standard Round
• O.D./I.D. Grinding • Cross Hole
• Lathe

Spline Development Re-sharpening

• Involute & Reconditioning:
• Inverted We offer immediate
• Serration reconditioning or rebuild
• Straight of worn or broken broaches.
• Angular

Surface Grinding: Polishing

• Flat Inserts
• Angular Form Inserts High Speed Welding
• Squares
• Hexagon Key Ways 24-Hour “Emergency”
• Form Inserts Turnaround Service:
• Serration Form Inserts We will provide the best
• “DD” Form possible delivery, quality
• Standard Key Ways and service for our customers.

Phone: (734) 467-5750 Email: apollobroach@att.net

Fax: (734) 467-5753 39001 Webb Ct. • Westland, MI 48185

APRIL 2011 65
 ees need to be able to view their work
through “green lenses.”
“When we hear about green workers in
the media, most people think of jobs in
alternative energy fields,” says Jeannine
Kunz, director of marketing and profes-
sional development at SME. “But the
reality is that just about any job can—and
should—be green. It’s about developing
skills within the current workforce so they
can identify opportunities to implement
environmentally friendly solutions on the
plant floor.”
In fact, the U.S. Bureau of Labor
Statistics recently came out with its offi-
cial definition of a green job. The first part
describes the jobs we already think about
as being part of the “green economy”:
Technical Solutions Jobs in businesses that produce goods
or provide services that benefit the envi-
Aerospace and Automotive Applications
ronment or conserve natural resources.
Multiple Start Gear It’s the second half of the definition that
Grinding Wheels stretches the current view of green jobs:
• Lower grinding forces
• New abrasive blends & bonds Jobs in which workers’ duties involve
• Lower grinding temperatures
• Increased porosity for higher stock making their establishment’s production
removal
processes more environmentally friendly
or use fewer natural resources.
SME worked with green subject-mat-
Gear Honing Benefits
ter experts to research and build the
• Flank correction
• Reduced operating noise Body of Knowledge (BOK) for the Green
• Longer service life
• Correction for distortion from harden- Manufacturing Specialist. The panel com-
ing process
pleted a job-task analysis for the green
elements in every production worker’s
job. This resulted in a BOK that reflects
Hermes Abrasives, Ltd.
524 Viking Drive • Virginia Beach, VA 23452 Toll free phone: 800.464.8314 the required knowledge and skills for suc-
PO Box 2389 • Virginia Beach, VA 23450 Toll free fax: 800.243.7637
cess in the field.
The SME Green Specialist Outcome
Assessment can be used by individual
practitioners or manufacturing enterpris-
es to measure current knowledge levels
and identify areas where training may
be needed. Training could be provided
by Purdue TAP—which developed its cur-
riculum based on the BOK, a Purdue TAP
partner—or by using online tools such as
SME Tooling U or other qualified training
programs. Practitioners can then choose
to sit for the exam to earn their Green
Manufacturing Specialist Certificate. For
additional information visit [www.sme.
org/green]. To learn more about Purdue
TAP’s Energy Efficiency and Sustainability
Program go to [www.purdue.edu/tap/
green].
66 gearsolutions.com
Mazak Certifies SME Tooling
U for VIP Technology
Partnership Program
Mazak has announced that SME Tooling
U, the leading provider of online manu-
facturing training programs, has been
named the newest member of Mazak’s
Value Inspired Partners (VIP) program.
Created from a desire to provide manu-
facturers with total solutions, the VIP
program promotes higher levels of coop-
eration among companies offering com-
plementary manufacturing products.
“SME Tooling U is very excited to be
part of the Mazak VIP program,” says
Chad Schron, SME Tooling U division
manager. “We work with Mazak to train
employees all over the world on manu-
facturing topics and Mazak technology
specifically.”
Mazak launched its VIP program in
August 2010. Inclusion in the VIP pro-
gram requires a company to provide
products and services that transcend
traditional supplier relationships and
meet the following criteria:
•B  e a recognized leader with unique,
innovative, and high quality products;
• Provide extensive pre- and post-sales
support;
• Add value to customer processes and
provide system solutions;
• M aintain a culture of ethical business
standards and practices.
“SME Tooling U represents an excel-
lent candidate for participation in the
VIP program,” says Brian Papke, presi-
dent of Mazak Corporation. “Given the
continuous investments that Mazak
makes in training seminars and events,
we have a great respect for what SME
Tooling U has accomplished and value
the working relationship we have with
them. We are pleased to welcome them
to the program.”
Members of the VIP program will work
with Mazak in product development and
the creation of training events and semi-
nars spanning a broad range of topics.
For more information please visit [www.
mazakusa.com/vip].
 advertiser
INDEX
COMPANY NAME................PAGE NO.
AJAX Rolled Ring and Machine................................................57
Allen Adams Shaper Services...................................................65
Apollo Broach Inc.....................................................................65
AWEA 2011.............................................................................56
Banyan Global Technologies.....................................................16
Bourn & Koch..........................................................................67
Broach House Manufacturing Inc..............................................65
Buffalo Gear.............................................................................55
Carl Zeiss IMT Corp.................................................................41
Circle Gear Co.........................................................................16
Clarke Gear Co........................................................................40
Cole Mfg Systems Inc..............................................................66
Composites Manufacturing 2011..............................................59
Delta Gear...............................................................................23
Drewco Workholding................................................................50
DT Technologies.......................................................................37
EASTEC 2011..........................................................................64
Engineered Tools Corporation (ETC)....................................34-35
Forest City Gear.......................................................................29
Gear Manufacturing Inc....................................................... 10,65
Gear Solutions Online...............................................................45
Gleason Corporation................................................................25
GMN USA................................................................................36
Hainbuch America....................................................................44
Hanik Corporation....................................................................67
Hermes Abrasives....................................................................66
High Performance Gear............................................................54
Hobsource Inc.........................................................................65
Ingersoll Cutting Tools............................................... 11,13,15,17
Innovative Rack & Gear Co.......................................................65
KAPP Technologies................................................................ IFC
KISSsoft USA LLC...................................................................12
Klingelnberg GmbH....................................................................2
McInnes Rolled Rings...............................................................58
Micro Surface Corp..................................................................40
MicroGear................................................................................38
Mitsubishi Heavy Industries America Inc.................................. BC
MOOG Inc...............................................................................36
New England Gear.....................................................................7
Niagara Gear............................................................................12
P&G Machine and Supply Co Inc..............................................66
Precision Gage Co...................................................................52
Process Equipment..................................................................37
Proto Manufacturing Ltd...........................................................39
R P Machine Enterprises Inc.....................................................60
Repair Parts Inc.......................................................................52
Riverside Spline & Gear Inc...................................................9,18
Russell Holbrook & Henderson.................................................51
Sandvick Coromant................................................................ IBC
Schafer Gear Works Inc...........................................................10
Seco Tools Inc.........................................................................27
The Broach Masters...................................................................4 www.hanikcorp.com
The Company Corporation.......................................................65
TMFM LLC...............................................................................47
CORPORATION
Toolink Engineering....................................................................1
Willman Industries....................................................................38

APRIL 2011 67

GS: I understand there’s an inter-
esting story behind your company’s
name and location.
AA: That’s true. My father, Joseph Arch,
founded Southern Gear in Miami. He was
originally from New England, where I grew
up, and he’d worked for Fellows as a tool
and cutter design engineer until 1933,
when he lost his job because of the Great
Depression. He worked for another com-
pany until 1946, when he launched the
Arch Gear Works in Boston. One thing I can
tell you about him is that he hated cold
weather from the day he was born, so we
spent our vacations down in Florida each
year. When he found out that a man who
was one of his best gear cutters was mov-
ing there he decided it was time to head
south himself, so he handed the reins of
Arch Gear over to my brother and opened
Southern Gear in 1957. He and my mother
would spend the summers up north and
the winters down south, which was perfect
for them. I joined Southern Gear straight
out of the Navy in 1968. Dad came to the
office well into his nineties, and he passed
away at 95, so we had a good 60 years
together. We had a wonderful relationship,
we were like best friends. My brother even-
tually decided that running a gear manu-
facturing company wasn’t for him, so Arch
Gear isn’t around anymore, but Southern
Gear is going strong.
Call (800) 248-5152 or go online to [www.southerngear.net].
68 gearsolutions.com
Q&A
allan Arch
president
Southern Gear & Machine, Inc.
GS: How have you weathered the
recent economic downturn?
AA: Very well, actually. We decided to
make certain capital investments, so we’ve
bought some new equipment and expand-
ed our capabilities. It’s funny to think
about how my father had 200 employees
at one time, and CNC technology allows
us to produce 10-15 times as many
gears as he could with just 80 people.
We’re also fairly well diversified in terms
of the markets we serve, so that helps
since one usually seems to be up while
another one is down. Plus we’ve always
been known for small-lot, high-precision
loose gearing for applications in the aero-
space, maritime, and defense industries,
just to name a few. One of the jobs I’m
proudest of involves parts we made for
the repair of the Hubble telescope. They
had to go back up there and mount it with
a corrective lens, you may recall, and our
gears operate the lens. When I see the
incredible images that Hubble has sent
back to earth since the repair, I get a real
kick thinking about how we played a role
in that. People come to us when precision
matters, and I think part of the reason for
that is because everyone here takes so
much pride in what we do. Back in 1987
I decided to adopt an Employee Stock
Ownership Plan, or ESOP, which basically
means that we’re an employee-owned com-
pany. When your employees know that they
have a stake in the company’s success,
then they’re willing to go the extra mile
when it’s called for, and employee reten-
tion improves so you don’t lose the knowl-
edge they’ve developed over the years in
your shop. We’ve got good people here,
and they do a great job.
To learn More:
GS: You strike me as someone with a
lot of enthusiasm for his profession.
Would you agree?
AA: Oh, yeah. You’ll find gears in almost
everything, or in the machines that make
or deliver those things. Being involved in
this industry lets you do and see things
that you never would have otherwise,
like working on vehicles used by the U.S.
space program on other planets. I enjoy
talking about what I do, as well. My alma
mater is the University of Maine, and I
had the dean of the engineering school in
“Being involved in this
industry lets you do
things you never would
have otherwise, like
working on vehicles for
the U.S. space program.”
here recently to take a tour of our opera-
tion. I introduced him to the dean of the
engineering school at Florida International
University, where I speak to the undergrad-
uates about manufacturing gears. I also
address members of the executive MBA
program at Nova Southeastern University
about the things I’ve learned over the
years. I tell them about the company,
how Dad started it, and about the ESOP
program, because business is really about
people. But to answer your question, yes,
I enjoy what I do... I love this business,
actually.