Materials Mattertooth tips

hot seataGMa UpDate

Q&a: zen CiChon InnovatIve Rack and GeaR

CoMpany profile: RedvIkInG enGIneeRInG

gearsolutions.comFEBRUARY 2013

GEARBOX VARIANT GENERATOR CAsE sTudIEs

CRACk TEsTING ANd HEAT TREAT VERIfICATION

Of GEARs usING Eddy CuRRENTTECHNOLOGy

E X T E N d I N G THE LIfE EXpECTANCy Of yOuR GEARBOX

kapp-niles.com 2870 Wilderness Place | Boulder, CO 80301 p: 303.447.1130 | f: 303.447.1131 | info-USA@kapp-niles.com

Estate Planning.

Invest in your future. Kapp-Niles machines are more than just an investment. They’re essential in

planning for the future of your estate. Our machines are built for the long haul, so you can pass them down for

generations to come – with 97% of our finishing machines still in operation since 1984. Plus, our quality service

and retrofitting capabilities allow you to stay current with changing technologies.

Invest in Kapp-Niles and invest in the future of your business.

KX 500 FLEX is ideal for single piece or series production of external spur or helical gears. Generating grinding or profile grinding, or a combination of both methods may be used.

Indiana Technology & Manufacturing Companies, Inc. (ITAMCO), left to right: Joel D. Neidig - Technology Manager Nobel Neidig - President Gary Neidig - Vice President

http://www.toolink-eng.com

Precise and productive.With the LCS product line a series of machines is now available that is characterized by their productivity and versatility.

Generating or profile grinding on one machine Dressable corundum and CBN tools Galvanic CBN tools Most economical grinding worm dimensions Short floor-to-floor times through automation Fast set-up for flexible gear finishing

Generating and profile grinding machines from Liebherr.

Liebherr Gear Technology, Inc.1465 Woodland DriveSaline, Michigan 48176-1259Phone.: +1 734 429 72 25E-mail: info.lgt@liebherr.comwww.liebherr.com The Group

With the LCS product line a series of machines is now available that is characterized

2007-017_13 AZ Aufbau LVT Schleifen_216x279-08_GB.indd 1 14.01.13 13:30

FEBRUARY 2013 3

Features

Company Profile: RedViking EngineeringBy Tim Byrd

“The challenges that we meet everyday well exceed what most engineers have to face. The rewards for meeting those challenges are terrific.”

Two Case Studies in the Mining Industry with the KISSsoft Gearbox Variant GeneratorBy Dr. Ing. U. Kissling

When designing gears, the size, weight, and manufacturing cost can be influenced to a great extent by both strategically splitting the overall reduction over the individual stages and by optimizing the geometric relationships.

Crack Testing and Heat Treat Verification of Gears Using Eddy Current TechnologyBy Dan DeVries

Eddy current testing offers fast, repeatable testing of gears and other critical metal components, a feature required in today’s modern manufacturing environment.

28

42

50

How to Minimize Downtime, Repair Costs and Inventories

by Extending the Life Expectancy of Your Gearbox

By Dan Rosseljong

A commitment to maintain your gearbox is paramount for this to work economically. When

you devise a plan to maintain your gearbox, your return on investment will be realized sooner and

your total cost of ownership will be reduced.

32

BroachmasterFP.indd 4 12/20/11 2:36:20 PM

FEBRUARY 2013 5

Departments

Gear Solutions (ISSN 1933 - 7507) is published monthly by Media Solutions, Inc., 266D Yeager Parkway Pelham, AL 35124. Phone (205) 380-1573 Fax (205) 380-1580 International subscription rates: $72.00 per year. Periodicals Postage Paid at Pelham AL and at additional mailing offices. Printed in the USA. POSTMASTER: Send address changes to Gear Solutions magazine, P.O. Box 1210 Pelham AL 35124. Publications mail agreement No. 41395015 return undeliverable Canadian addresses to P.O. Box 503 RPO West Beaver Creek Richmond Hill, ON L4B4R6. Copyright 2006 by Media Solutions, Inc. All rights reserved.

No part of this publication may be repro-duced or transmitted in any form or by any means, electronic or mechanical, including photocopy, recording, or any information storage-and-retrieval system without per-mission in writing from the publisher. The views expressed by those not on the staff on Gear Solutions magazine, or who are not specifically employed by Media Solutions, Inc., are purely their own. All "Industry News" material has either been submitted by the subject company or pulled directly from their corporate web site, which is assumed to be cleared for release. Comments and submis-sions are welcome, and can be submitted to editor@gearsolutions.com.

8Trends, data, and developments to keep you aware of what’s happening with your colleagues in the gear-manufacturing industry around the

country and world.

Industry News

56News of products, equipment, and resources from across the manufacturing spectrum that will help propel your

company toward success.

Product Showcase

Zen Cichon

prEsidENTinnovative rack and Gear

68Q&A

24densification technologies in powder meal gears: if pores are eliminated where high stress occurs, gear performance will improve.

Materials MatterAnders Flodin

26As manufacturers of furnaces, we are obligated to make sure that all parties involved with installation are trained in the proper operation.

Hot SeatJack Titus

25straight bevel gears are usually produced on special bevel gear generators. The choice of tooth forms is limited to those forms that can be most easily generated.

Tooth TipsWilliam P. Crosher

61MACHINERY

65MARKETPLACE

67ADVERTISER

INDEX

American Gear ManufacturersAssociation

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

Resources

FEBRUARY 2013 | VOLUME 11 / NO. 02

19

The most exciting part of my job is getting to hear the enthusiasm everyone seems to have for this industry. Even better is hearing how the enthusiasm is growing, spreading throughout every region of the country. Everyone I speak with, from CEOs to tooling specialists to marketing directors, talks about the solutions rather than the problems. And that’s exactly what Gear Solutions wants to be — part of the solution.

From everything we hear, things are getting better. Apprenticeships are being created by employers and sought after by future-employees in manufacturing com-panies all over the U.S. Companies big and small are getting more involved with community colleges, creating manufacturing programs, and advocating vocational training. These things will work. These students, standing on the shoulders of the industry giants before them, will spearhead the manufacturing breakthroughs of the 21st century.

Even in the past year, gear design has been revolutionized by some of the bright-est minds in the country. RedViking Engineering, this month’s company profile focus, has been designing and building component test machines to test helicopter trans-missions. “We did (this) by equipping ourselves with some of the brightest minds we could find,” Brooke Elliott of RedViking remarks. “We have a variety of experts from different fields on board, along with some of the brightest kids coming out of school. We’re constantly trying to educate ourselves and each other, and consequently we are growing as a group that will be the experts in the gear field.”

Our February issue of Gear Solutions is devoted specifically to gear design and inspection — an issue filled with solutions for challenges ranging from noise and vibration analysis (Dan DeVries) to a case study using the KISSsoft Gearbox Generator (Dr. Ing. U. Kissling) to the avoiding the dreaded “D” word: Downtime (Dan Rosseljong). Gear Solutions’ columnists continue their monthly effort to give our readers their expertise on heat treatment, materials, and “Tooth Tips.” Jack Titus, as usual, provides some comic relief with his discussion of “why you shouldn’t slam the furnace door,” and William P. Crosher and Anders Flodin continue their in-depth lectures on bevel gears and powder metal technology, respectively.

Growth is a common goal among the men and women in the gear industry with whom I speak every day; yet, growth doesn’t always mean bigger buildings, more employees, or new locations. Zen Cichon’s Innovative Rack and Gear services the oil, aerospace, steel, marine, automation, machine tool, medical, and precision instrument industries, and supplies gear racks to many well-known catalog compa-nies. Zen discusses how networking, advertising, and appearing at the Gear Expo have all played a part in their remarkable growth in the past eight years.

As long as there are challenges, there will be men and women stepping up to meet those challenges. Within this industry, Gear Solutions is here to document the innovative strategies for solving problems and the tireless workers behind the solu-tions. We’re proud of our name, and we stand by it.

Thanks for Reading,

Tim Byrd managing editor

Gear Solutions magazineeditor@gearsolutions.com

(800) 366-2185 x205

6 gearsolutions.com

Published by Media solutions, inc.P. O. BOx 1987 • Pelham, al 35124

(800) 366-2185 • (205) 380-1580 fax

David C. CooperPuBlisher

Chad MorrisonassOciate PuBlisher

EdiTOrLETTERFROM THE

Dav id C . C o operPresident

C had Mor r i s on Vice President

Ter e sa C o operOPeratiOns

Contributing writersWilliam P. crOsher

dan deVriesanders flOdin

dr. ing. u. Kisslingdan rOsseljOng

jacK titus

eDitoriALTim Byrd

managing editOr

Stephen SiskassOciate editOr

sALesChad Morrison

assOciate PuBlisher

Michael SellaroliregiOnal sales manager

CirCuLAtionTeresa Cooper

manager

Kassie HugheycOOrdinatOr

Jamie Willettassistant

ArtJeremy Allen

creatiVe directOr

Rebecca AllengraPhic designer

Michele HallgraPhic designer

Coop wants to use this one for the website

Vertical Logo Horizontal Logo

8 gearsolutions.com

INDUSTRYNEWS

Ingersoll Cutting Tools has long been one of the world’s leading suppliers of metal removal tooling. Since their first cutting tool patent in 1889, Ingersoll has strived to provide the most innovative and pro-ductive metal removal solutions on the market. They pioneered the development of indexable carbide end mills and were the first ones to introduce the on-edge insert configuration. Bob Arndt, manager of carbide manufacturing in Rockford, Illinois says, “We take great pride in producing

a quality product supported by superior service to our customers.” To advance its grinding capabilities and improve the work-ing environment, Ingersoll Cutting Tools has switched to Sinto-Grind IG, a synthetic based grinding fluid, to ensure reliable high quality and improved performance.

The Rockford plant is a significant US manufacturer of industrial tungsten car-bide high-feed inserts for the automotive, aerospace, and agricultural industries. “We have invested heavily in leading edge CNC

equipment to retain our quality edge and delivery promise.

“The key to manufacturing a good tool,” Arndt says, “is in controlling the grinding process through a variation of principles. Our tools need to have a long life that starts with a clean, chip-free cutting edge. Therefore, close monitoring of the grind-ing speeds/feeds, grinding wheel, and especially the grinding fluid, is critical.” Synthetic grinding fluids developed and pro-duced by oelheld U.S., Inc. coupled with a

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

New products, Trends, services, and developments

Synthetic Intelligence Technology Pushes Ingersoll Cutting Tools Company to New Limits

FEBRUARY 2013 9

clever filtration system, meet the demands of Ingersoll Cutting Tools exactly. With the installation of a fine filtration system and a switch to SintoGrind IG, a high-performance synthetic grinding fluid, new benchmarks have been set in carbide production at Ingersoll.

The benchmarks are:• No cobalt leaching on the surface of the

ground inserts• 80% less oil consumption• Wheel life increase• 5% faster machining on light sharpening

applications• 30% faster machining on heavy fluting

and top and bottom grinding• Easier cleaning of the working equipment

(electrostatic mist collectors etc.)

These benchmarks, among others, help to generate a much nicer, cleaner, and healthier working environment at Ingersoll Cutting Tools. For additional information please visit www.ingersoll-imc.com/www.oelheld.com

Inductotherm Group to Add Clinton Machine to Group FamilyInductotherm Group is pleased to announce the addition of Clinton Machine of Ovid, MI to the Inductotherm Group family.

“Clinton Machine brings with it years of experience in material handling equipment, specifically in the bar, tube, heat treating, and other production machinery areas,” said Gary Doyon, president/CEO of the Inductotherm Group. “We are excited with this expansion of the Inductotherm Group. Adding the spe-cialized capabilities of Clinton Machine will provide additional value to our current clients and help the corporation to expand into new markets.”

“The inclusion of Clinton Machine into the Inductotherm Group will allow us to provide better material handling systems to our heat treating, shrink fitting, and forging system clients,” said Doug Brown, president/COO of Inductoheat, Inc. “This new partnership is especially exciting to Inductoheat, as both companies compliment each other quite well.”

Inductoheat, Inc., which is leading the world in induction heating technologies, is one of forty companies making up the Inductotherm Group. As a multi-technology global organiza-

tion, Inductotherm Group serves the thermal processing industry by manufacturing and marketing a diverse range of products and services, some of which include: Inductotherm induction melting systems, Inductoheat and Radyne induction heating equipment, Thermatool pipe and tube welding equipment, and Consarc vacuum melting and refining systems.

For information regarding the Inductotherm Group, visit www.inductother-mgroup.com.

Solar Atmospheres of Western PA Welcomes New Regional Sales ManagerSolar Atmospheres of Western PA (SAWPA) has named John (Jack) Giacobbi as their new

10 gearsolutions.com

regional sales manager. Mr. Giacobbi will manage established accounts and develop new business in the Midwest US. He previously held a position with similar responsibilities as an account manager at Bodycote in Rochester, NY.

“The expansion of our sales team fur-ther strengthens our ability to meet the needs of our customers,” noted Robert Hill, SAWPA president. “Jack’s compre-hensive understanding of heat treating sales and processing will help us con-nect with new customers and improve our client service. As an award-winning sales person with a proven track record, we are confident that Jack will make a valuable contribution to our continued success.”

Mr. Giacobbi holds a BA in business administration from Columbia College. Find out more at www.solaratm.com, or call 1-855-WE-HEAT-IT.

Dontyne to Develop Convoloid LTCA with Genesis PartnersDontyneTM Systems has entered into an agreement with Genesis Partners to develop software for the tooth contact analysis of their Convoloid® gear form. Convoloid is a conformal and conjugate gear tooth form exhibiting much lower contact stresses and improved bending strengths compared to its involute equiv-alent in size, center distance, and face width; yet its manufacture is compatible with the world’s existing gear manufac-turing infrastructure. The type of analysis available will be analogous to the invo-lute helicoid analysis tools in the gear production site. Genesis Partners have demonstrated in testing that this form of gearing has significant benefits over involute helicoid equivalent by direct testing in wind turbine gearboxes. There will be regions within the envelope of operation of any application where either involute helicoid or Convoloid would be a better selection. The new software will enable a cost-effective analysis to iden-tify optimum choice for testing. Just as with Dontyne’s involute helicoid equiva-lent, there will be links to manufacturing and inspection for efficient production. The Convoloid type of analysis will be

exclusive to Dontyne and will be avail-able for testing in March. More informa-tion is available at www.dontyne.com.

Weinberg Capital Group Announces Acquisition of Overton Chicago Gear, by Newly Formed H-D ManufacturingWeinberg Capital Group (WCG) has partnered with The Riverside Company (Riverside) and Hicks Equity Partners (Hicks) to acquire Overton Chicago Gear Corporation (Overton), a manufacturer and distributor of large diameter, pre-cision gears serving the wind power, energy exploration, mining, locomotive, marine, steel, and steel processing industries. Overton is the first acquisi-tion for H-D Advanced Manufacturing Company, a holding company formed by the partners to specialize in a wide vari-ety of heavy-duty, precision-engineered parts.

With a history dating to 1888, Overton has built a global reputation for quality by meeting the demands of challeng-ing industries. Customers within these industries require high-precision parts that are durable and reliable enough to withstand harsh operating environments. Overton designs and manufactures cus-tom helical, spur, herringbone, bevels, double enveloping worm, and other open or loose gears as well as gearboxes. The company employs more than 200 people at three manufacturing facilities in the Chicago area.

Based in Pittsburgh, H-D Advanced Manufacturing will be led by CEO Christopher DiSantis and CFO Dale Mikus. Mr. DiSantis brings 20 years of industrial management experience, most recently as CEO and president of Latrobe Specialty Metals. Mr. DiSantis also served as president and COO of Hawk Corporation. At Hawk Corporation, Mr. DiSantis partnered with WCG prin-cipal Ronald E. Weinberg to build a global manufacturer of friction prod-ucts for brakes, clutches, and transmis-sions used in airplanes, trucks, con-struction and mining equipment, farm equipment, and recreational and per-formance automotive vehicles. In 1998

FEBRUARY 2013 11

Hawk was taken public on the New York Stock Exchange trading under the symbol HWK. After more than 20 years of success-ful operation, Hawk was sold to Carlisle Companies, Inc. (NYSE: CSL) in December 2010 for $413 million.

“We are very pleased to once again be partnering with Chris DiSantis,” stated Chip Weinberg, managing director & principal at WCG. “Overton is a world class company and an excellent initial platform. Under Chris’ leadership and with the assistance of our other partners, we look forward to building a global leader in the precision machining of parts for extreme operating environments,” added Mr. Weinberg.

WCG, Riverside, and Hicks are active-ly seeking add-on opportunities for H-D Advanced Manufacturing in the gearing industry and within other heavy duty, pre-cision-engineered component sectors. For more information, visit www.weinbergcap.com or www.oc-gear.com, or call 630-543-9570.

Local Couple Opens Bolingbrook Metal SupermarketsShirin Lakdawala and her husband Sabeer Cherawala, of Lemont, Illinois opened the newest Metal Supermarkets® store, the world’s largest supplier of small quan-tity metals, in the Chicagoland area. Metal Supermarkets Bolingbrook, on 999 Remington Blvd., began providing Southwest Suburban businesses and con-sumers with superior customer service and the highest quality metal products avail-able. Customers can buy any size or type of metal they need, quickly and easily, and with no minimum order requirement.

“We are excited to further expand the company’s footprint in Chicagoland and look forward to working with Shirin and Sabeer to further develop the Metal Supermarkets brand,” says Stephen Schober, Metal Supermarkets president and CEO. “With so much industry in the Southwest Suburbs, the Bolingbrook store is in a great position to thrive.”

Prior to starting the Metal Supermarkets franchise, Shirin and Sabeer owned and operated a Days Inn franchise in Northern Indiana for more than 17 years. After sell-ing their hotel business they sought a business-to-business concept that would

enable them to have family members involved, was stable, and had limited com-petition. The couple investigated numerous franchise systems and determined Metal Supermarkets to be the right choice.

Sabeer grew up in India in the metal industry as his father owned a metal distribution business similar to Metal Supermarkets. He has extensive experi-

ence and family relationships in the met-als business. His brothers have continued the family business and own locations in Mumbai, Dubai, and Vancouver.

“We were looking for a business that would allow us to apply the skills, like the customer service we mastered in the hotel business. More importantly, we wanted to be in a business with more

12 gearsolutions.com

traditional operating hours, so we could share more family time together,” says Shinir Lakdawala, co-owner of Metal Supermarkets Bolingbrook. “We liked the Metal Supermarkets business model and figured we could get back into the fam-ily business. For Sabeer, this transition marks a complete circle as he started in this industry working in his father’s metal distribution store when he was a teenager.”

For more information, visit www.MetalSupermarkets.com or franchise.metalsupermarkets.com, or call 1-800-807-8755.

SKF Signs Contracts Worth 1 Billion SEK with Audi AGSKF has signed contracts with Audi for the delivery of SKF components for use on a range of vehicle models. The con-tracts, estimated at nearly 1 billion SEK, include the delivery of four different ver-sions of wheel bearing units for the wheel ends and a range of bearings for the new double clutch transmission.

“Together with our customers, we strive to deliver optimized solutions to meet their needs. We are proud to be a development partner with Audi and I am happy they have confidence in SKF’s knowledge engineering,” says Tryggve Sthen, president, SKF Automotive.

The SKF wheel bearing units include an active ABS system, and the flexible design provides a cost-effective solution for a range of vehicles using Audi’s new modular MLB Evo-platform. The transmis-sion and clutch bearings are designed to meet Audi’s specific double-clutch trans-mission requirements.

The integrated hub-bearing unit, origi-nally conceived by SKF in the late 1930s, is now the most common solution for car and light commercial wheel-bearing applications. Today, nearly, 90 million vehicles are riding on SKF wheel bear-ings and hub units. Deliveries will begin in 2013 from SKF factories in Spain and Italy. For more information, visit www.skf.com, or call the media hotline at +46 31 337 2400.

Zagar Appoints Absolute Machine Tools, Inc. as Exclusive Distributorfor Deep Hole DrillingZagar, Inc., the exclusive importer of Precihole™ Machine Tools Ltd., has appointed Absolute Machine Tools of Lorain, Ohio as its exclusive Midwest distributor for its deep hole drilling solu-tions. Absolute will represent Precihole exclusively in the areas of Michigan, Ohio, Indiana, Kentucky, West Virginia and Western Pennsylvania.

“We are very excited about becoming part of the Absolute Machine Tool Group,” stated Jim McGaffin, Sales and Marketing Director for Zagar, Inc. “The Precihole line of deep hole drilling, honing, skiving, burnishing, and BTA drilling machines is a very appropriate complement to Absolute’s existing machine tools lines of You Ji, Johnsford, Tongtai, Ecoca, and Accutex EDM”. Many of the customers served by Absolute have deep hole drilling applications and the solution s can now be purchased from an one supplier.

PECo - A Family of Metrology Machines that’s Right For You!

FEBRUARY 2013 13

Absolute Machine Tools owner Steve Ortner introduced the Precihole line to their sales force at offices in Lorain, OH; Livonia, MI; and Mason, OH at the end of December, and alreadyhave several projects working. Absolute will be a full service distributor, providing service and installation... with support for applications and parts from Zagar. Precihole Machines are built to perform gundrilling, BTA drilling, honing, reaming, counterboring, trepanning, skiving, burnish-ing, and pull boring. These applications represent key solutions for industries such as firearms, hydraulics, gas and oil, aero-space and defense, and automotive and medical.

Improving American productivity for sev-enty-five years, Zagar, Inc. manufactures and distributes a range of workholding solutions, deep hole drilling machines and solutions, multi-spindle drill and tap heads, feed units, and robotic end effectors. The company’s expertise is machining both ferrous and non-ferrous materials for industries such as automotive, aerospace, electrical, medical, off-road construction equipment, hydraulic, pneumatic, and high-production drilling and tapping. For more information, call (216) 731-0500 or visit www.zagar.com

NORD Drivesystems Gearmotors Are Being Used On The Pradier Quarry Site In The South Of FranceThe IECS Company, specializing in the manufacture, assembly, and maintenance of quarry and sand pits equipment has chosen NORD gearmotors to power the new aggregates production unit of the Pradier Group. The quality of service, especially in terms of reactivity and the performance of IE2 motors have made the difference. The French Group Pradier produces 400,000 tons of concrete blocks and interjoists per year, which are intended for building mate-rial suppliers. Pradier Carrières, founded in 2010, has thus opened its first operating site in 2011 in Mondragon in the south of France. The quarry consists of a deposit of about 375 acres and 20 million tons of ore, with a mining permit for 450,000 tons per year over 30 years. 350,000 tons are then transported by road and 100,000 tons by

river. The processing plant is located near the deposit (1 km by conveyor) and has a production capacity of 400 tons per hour. The IECS Company completed the whole installation, which provides ore crushing, screening, and conveying of aggregates to their shipping points. “We buy NORD Drivesystems helical bevel gearmotors reg-ularly,” says Mr. Cachot, IECS Manager.

In total, there are 37 NORD Drivesystems helical bevel gearmotors, SK9042.1 & SK9072.1 models powered by IEC B5/IE2 motors used in the Pradier site. “We have a very good relationship with NORD. It is a human-sized company — they are very reac-tive. When we commissioned the facility, the motor model had to be changed for two units which ratings were not high enough.

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We called NORD and 36 hours later it was changed. The NORD sales manager is always available to help on the project. He reacts very quickly.”

A new emergency assembly and ship-ping service is offered to all customers since the spring of 2011. Whether it’s a motor or a gear motor, with or without variable frequency drive, painted or not,

the company aspires, provided the com-ponents are available, to assemble and ship on the same day anywhere in France, for all orders placed before 4:30pm. To achieve this fast response time, the processes, inventory levels, and logistics were thoroughly reviewed in 2011. The same service has been set up for spare parts. Energy consumption was obviously

an important aspect of the facility. Again, NORD stood out by offering IE2 motors. To comply with new and more demanding standards, in terms of energy efficiency, NORD has made many improvements to its IE2 motors. For example, superior materials are used in the stator, the qual-ity of the plates is better, more copper was used, and the windings have been optimized. These efficient motors are naturally beneficial to users. In addi-tion to better performance, the motors run cooler and have a longer operating life. These improvements also result in greater power reserve, which opens up new possibilities in terms of drive sys-tems design

For more information, visit www.nord.com.

Luren Chicago Moves Into New Sales and Service Center

Centrally located in Schaumburg, Illinois, Luren’s new sales and service center for North America features a nice showroom to display their gear grinding machines. Their new address is 707 Remington Road, Suite 1, Schaumburg, Illinois 60173. This location was chosen for its central location to both east coast and west coast gear manufacturers. The old office was also located in Schaumburg, Illinois but with a very exciting and suc-cessful 2012, this facility was not able to keep up with Luren’s growing needs in the North American market.

The sales department headed by Darian Ditzler will also operate out of this loca-tion. Luren’s focus on selling gear cutting tools, gear grinding machines, multi-purpose gear cutting tool sharpening machines and spinning pumps in North America will not change, and you can expect even more great products from the leading Asian gear cutting tool manufac-

FEBRUARY 2013 15

turer and Taiwan’s only gear cutting tool and gear grinding machine manufacturer in 2013.

The service arm of Luren will also be conducted and coordinated out of this facility. With factory-trained technicians located right in the U.S. for their custom-er’s on-going support, Luren has a multi-level approach to address each and every challenge their customers may face. Offering both technical support and gear manufacturing solutions, Luren hopes to continue to be a valuable resource for gear manufacturers.

New for 2013, Luren will display their newly developed LGA-2812 CNC gear generation grinding machine at the 2013 Taiwan Industrial Machine Tool Show (TIMTOS) in Taipei, Taiwan on March 5 -10. With a Siemens 840D sl controller, Luren-designed Windows-based interface, an advanced direct drive motor (besting belt driven grinding machines), and a plethora of other advanced components and features, Luren’s LGA-2812 gear generation grinding machine is sure to impress. For more information, visit www.luren.com/tw.

Gear Dynamics And Gear Noise Short Course to be Held at The Ohio State University Department of Mechanical and Aerospace Engineering in Columbus, Ohio April 29 – May 2, 2013The purpose of this unique short course is to provide a better understanding of the mechanisms of gear noise gen-eration, methods by which gear noise is measured and predicted, and techniques employed in gear noise and vibration reduction. Over the past 34 years more than 1750 engineers and technicians from over 355 companies have attended the Gear Noise Short Courses. Topics discussed will include:

• Gear Whine and Rattle• Transmission Error - The Main Source• Measurements for Gear Noise Diagnosis• Noise, Vibration and Harshness Issues• Shaft and Gear Tooth Dynamics• Profile Design, Tolerancing and

Manufacturing

• Transmission Paths and Housing Acoustics

• All Types of Gears including Hypoids• Noise and Vibration Reduction

Techniques• Use of Practical Demonstrations• Demo of OSU-GearLab Computer

Software• Advanced Research Topics

The course is of particular interest to engineers and technicians involved in the analysis, manufacture, design specifica-tion, or utilization of simple and com-plex gear systems. Industries that find this course helpful include the automo-tive, transportation, wind-energy, process machinery, aircraft, appliance, general manufacturing, and all gear manufactur-

16 gearsolutions.com

ers. The course material is covered in such a way that the fundamentals of gearing, gear dynamics, noise analysis, and measurements are covered. This makes the course appropriate to the gear designer with little knowledge of noise analysis as well as to the noise specialist with little prior knowledge of gears. A fea-ture of this course is the interspersing of

demonstrations with lectures. The exten-sive measurement and computer soft-ware capabilities of the Gear and Power Transmission Research Laboratory pro-vide for this in a simple, non-commercial manner. On the first day, the lecturers discuss why even perfect gears make noise. They present in both qualita-tive and quantitative terms how gear

design parameters and manufacturing errors affect noise. The concept of gear transmission error, one of the major contributors to gear noise, is developed, and methods of predicting transmission errors from design and manufacturing data are presented. Participants get a clear physical insight into the problems they face and how they may apply course knowledge to help solve their gear noise problems. On the second day, lecturers concentrate on gear system dynamics and acoustics, gear rattle, and advanced signal processing. The third day’s lec-tures briefly discuss the sources and simulation models of gear rattle and the activities of the Gear and Power Transmission Research Laboratory, as well as spending several hours in the case history workshop.

This novel approach to discussing “real life” gear noise and dynamics problems has been used in this course since its inception. The workshop, which has been lauded by past attendees for its practical flavor, takes place on the last day of the course. The purpose of this workshop is to allow the course instructors and participants to interact and to discuss gear noise case histories presented by course attendees who need not reveal any proprietary information. Course attendees are asked to present a brief synopsis of problems they have encountered or of a procedure they have used for gear noise analysis and reduc-tion. Possible approaches to solve each problem are discussed.

Throughout each course, laboratory or computer software demonstrations are used to illustrate gear noise measure-ment and analysis techniques. The facili-ties of the Gear and Power Transmission Research Laboratory and the Acoustics and Dynamics Laboratory are used for these demonstrations.

The round table discussions on Day 4 are intended to foster interactive prob-lem solving discussions on a variety of topics such as:

1. Application of basic concepts covered in the lectures to practical problems attendees may have.

2. Advanced computer modeling meth-

A progressive gear manufacturer understands it needs to go above and beyond traditional expectations. Today’s customers demand – and deserve – the latest technology, a wide range of capabilities and an unrelenting commitment to prompt and effective customer service. When it comes to exceeding expectations, Schafer Gear is truly light years ahead. Our investment in the latest production equipment assures that we can provide gears for many industrial applications including transportation, medical, mining, gas and energy, agricultural equipment and many specialty applications. And every gear we make comes with one thing standard – the willingness to go to the ends of the earth to serve our customers well.

Find out more at www.schafergear.com or call us at 574-234-4116.

FEBRUARY 2013 17

ods used for transmission errors, geared system dynamics, gear rattle, etc.

3. Experimental methods for casing dynamics, and acoustics, advanced signal processing, transmission error measurement, etc.

4. Discussion of pertinent literature and prior approaches utilized to address difficult problems. Parallel sessions will be organized to suit the needs of attendees.

Dr. Donald Houser is the course orga-nizer and will lecture on gear noise measurement and gear modeling. He is Professor Emeritus of Mechanical Engineering and Founder of the Gear Dynamics and Gear Noise Research Laboratory at Ohio State. He has been active in gear dynamics research for over 45 years and has served as a consultant in this field for numerous companies. Dr. Houser is past chair-man of ASME’s Power Transmission and Gearing Committee, past chairman of ASME’s Gear Noise Committee, a member of the AGMA Noise Committee, and author of gear noise chapters in The Gear Handbook (D. Townsend, editor) and Handbook of Noise and Vibration Control (M. Crocker, editor). Dr. Rajendra Singh is The Donald D. Glower Chair in Engineering and Director of the Acoustics and Dynamics Laboratory at Ohio State. He has published more than 375 articles and is well recognized for research in geared system acoustics, bearing-casing dynamics, gear rattle analysis, and non-linear driveline dynamics. He is a fellow of ASME, ASA, SAE, and INCE/USA, and has received several national awards for both teaching and research. Dr. Singh has developed and teaches an innovative graduate course sequence in automotive noise and vibration control in partnership with General Motors. He has served as the president of the Institute of Noise Control Engineering in 2003.

Advance registration is required and should be completed no later than April 15, 2013. Applicants are accepted on a first-come, first-served basis to the limit of the course. However, the university reserves the right to limit admission to

the best-qualified in order to give them maximum benefit. Tuition payment is expected with registration, but arrange-ments for payment must be completed in advance of the starting date. Full tuition refund is made if cancellation is received by April 15, 2013. Checks should be pay-able to: The Ohio State University. The agenda, nearby hotels, parking, airport

transportation, and other relevant infor-mation will be sent upon registration or they can be viewed on the GearLab web-site (http://www.gearlab.org/). Contact Jonny Harianto (614-688-3952, harian-to.1@osu.edu) for registration informa-tion. Dr. D.R. Houser (614-292-5860, houser.4@osu.edu) should be contacted for technical information.

FEBRUARY 2013 19

Jan AlfieriAGMA Education Manageralfieri@agma.orgwww.agma.org

American Gear ManufacturersAssociation

You never know where you’re going to get the next great idea. AGMA’s new project started with a serendipitous meeting with Jeff Reynolds, purchasing manufacturing engineer/gear specialist at Rolls-Royce at the Gear Expo in 2011.

Jeff was interested in working with AGMA to develop a matrix that would define the re-quired skills and identify training programs for positions such as gear inspector, gear manufacturing engineer, and gear design engineer. The AGMA Education Advisory Council members enthusiastically endorsed the project and appointed an education task force, led by Jeff, to tackle the issue.

Over the last seven months, the AGMA education task force developed a skills as-sessment tool for the gear industry. This pro-cess involved identifying the job functions to be analyzed, the major areas of knowledge required by each job, and the skills necessary for success in each of these areas.

The task force identified specific skills, such as: Using micrometers and other tools, how to check dimensions, measure hard-ness, etc. The tool will guide users through a list of eight job positions, then outline five sets of skills required to complete those tasks, and the competency requirements of each skill.

As an example, for the gear inspector job function, the task force identified five major areas of knowledge: Blueprint read-ing and math, gear and spline nomencla-ture, gear inspection and analysis, gage R&R and process capability, and gaging basics and use.

The assessment is conducted when the employee’s supervisor rates the employees understanding and ability in each of the de-tailed skills areas; some have as many as 18 required skills. There are columns for listing the employer’s minimum requirement for a skill and the actual rating (0 to 4) of the em-ployee’s skill level.

Supervisors can complete an assessment for each employee. Some job descriptions have core skills in common. The analysis of the com-mon skills along with the competency levels will assist supervisors in ascertaining which em-ployees would be best suited for cross-training. Identified deficiencies can be addressed with additional training and education.

Using the scale shown in the table below, reviewers enter the rated score of 0 - 4 in the actual column for each skill in the work-sheet. The scores are automatically totaled and added into the “overall competency” table with the results being also shown in the “skills assessment” graph in each assess-ment. A red value in the “skills assessment”

AGMA Rolls Out a New Skills Assessment Tool

20 gearsolutions.com

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

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

Plastics Gearing Committee Meeting February 5-6, 2013 Atlanta, GA

Gear Materials: Selection, Metallurgy, Heat Treatment, and Quality Control February 6-8, 2013 Clearwater Beach, FL

Wind Turbine Committee Meeting February 6-7, 2013 Denver, CO

Spline Committee Meeting February 7, 2013 WebEx

Powder Metallurgy Gearing Committee Meeting February 7-8, 2013 Atlanta, GA

Computer Programming Committee Meeting February 7, 2013 WebEx

Sound and Vibration Committee Meeting February 11, 2013 WebEx

Helical Enclosed Drives High Speed Units Committee Meeting February 12-13, 2013 Orlando, FL

Mill Gearing Committee Meeting - subcommittee 6015 February 19-20, 2013 AGMA Headquarters - Alexandria, VA

Doing Business with the US Federal Government February 27, 2013 1:00 pm - 2:30 pm Eastern time Webinar

Lubrication Committee Meeting February 27-28, 2013 Orlando, FL

Cutting Tools Committee Meeting February 28 - March 1, 2013 Orlando, FL

Helical Gear Rating Committee Meeting March 5-6, 2013 Chicago, IL

Mill Gearing Committee Meeting - subcommittee 6014 March 7, 2013 WebEx

Metallurgy & Materials Committee Meeting March 7, 2013 Rosemont, IL

Gearbox CSI - Forensic Analysis of Gear and Bearing Failures March 12-14, 2013 Baltimore, MD

Basic Training for Gear Manufacturing April 8-12, 2013 Chicago, IL

Hannover Messe 2013 April 8-12, 2013 Hanover, Germany

Fine Pitch Gearing Committee Meeting April 9-10, 2013 Hartford, CT

Flexible Couplings Committee Meeting April 16-17, 2013 San Antonio, TX

2013 AGMA/ABMA Annual Meeting April 25-27, 2013 Carlsbad, CA

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graph reveals an area of concern that indicates training may be re-quired.

This tool encourages companies to assess new hires as well as current employees, and to provide a pathway for training and ad-vancement. It can also provide individuals with tools to analyze their own competencies and skills gaps and can be used to justify taking courses to fill those training gaps.

The actual assessment tool is an editable Excel file that will allow users to customize it for the their company and their job functions.

Jobs Functions are:Gear Manufacturing EngineerGear Inspector Gear Hobbing OperatorGear Shaping OperatorGear Grinding OperatorGear Design EngineerGearbox Design Engineer

In developing the skills assessment tool, the task force identified a second phase, which is a training gap assessment. The training gap as-sessment helps to determine the training resource needed for each skill. When the sheets are completed for each individual, an analysis can be performed to determine proficiency gaps within each job description, allowing a path to be established for individual and team improvement with suggested training options. By creating the training gap assess-ment, the task force reveals areas where classes need to be developed. This portion of the skills analysis tool is a work in progress and will be released at a later date.

The initial skills assessment tool has been developed and is on the AGMA website (www.agma.org) as a customizable Excel file for AGMA members only.

Special thanks go to the members of the task force: chair Jeff Reyn-olds, Rolls-Royce; Briggs Forelli, Precision Gear Incorporated; Robert Maggetti, Triumph Gear Systems-Macomb, Inc.; Tom Marino, Gear Technology; Rustin Mikel, Forest City Gear Company; Matt Mondek, Reliance Gear Corporation; and Robert Sakuta, Delta Gear.

AGMA Rolls Out a New Skills Assessment Tool (continued)

FEBRUARY 2013 21

fOReNSIC ANAlYSIS Of GeAR & BeARING fAIlUReS – USefUl TOOlS fOR OPTIMIzING GeARBOx deSIGN

March 12-14, 2013 Hyatt Regency Baltimore on the Inner Harbor, Baltimore, MD

Instructors:Raymond Drago, Chief Engineer – Gear Technologist, Drive Systems Technology, Inc.Joseph W. Lenski, Jr., Senior Bearing Engineer, Drive Systems Technology, Inc.

Determining the cause of a failure in a gearbox is like a “who done it” mystery. Why did the gearbox fail? Was it the bearings, the gears, or the environmental stresses?

This seminar, taught by Raymond Drago, P.E., and Joseph W. Lenski, teaches the forensic analysis of failed gearboxes, including the fol-lowing topics:

• The role of careful forensic analysis of gearbox failures in future gearbox design

• Bearings and gear types• Limitations of bearings and the gears they support • How to optimize bearing and gear combinations

Gearbox failures are not always related to predicted bearing life and gear service factor calculations. Forensic analyses of gear and bearing failures show that only a few of these failures are the result of true fatigue.

Many failures are the result of other contributing factors, often of such magnitude that they overshadow the basic gear and bearing rat-ing considerations. Therefore, careful evaluation of the forensic analy-sis is essential during the design process to achieve the best gear and bearing performance.

Furthermore, understanding gearbox bearing failures is critical in eliminating them in future designs. Forensic analysis will determine the root cause and then the designer must determine what has to be done to eliminate this root cause in future designs.

Actual data based upon the presenter’s own gear design for the application and rolling element bearing experience will be presented. The presentation is illustrated with numerous photographs and many case study synopses are discussed to provide real world examples of both failures and preventative measures based on an understanding of the failures.

The objective of this seminar is to provide a better understanding of various types of gears and bearings and educate the designer of the limitations and capabilities of rolling element bearings and the gears that they support, so that the designer can properly apply the best gear-bearing combination to any gearbox, whether simple or complex.

In addition to being colleagues for more than 40 years, the seminar instructors have had the great privilege of working directly together as an integrated “bearing/gear team.” Learn from this experience to minimize your problems and maximize your successes in future gear-box bearing designs. It is our belief that a good gearbox designer is only as good as his or her “bag of tricks!” Join us and fill your personal bag of tricks.

For more information or to register for this seminar, visit www.agma.org or call 703.684.0211.

Expert PresentersWe survived the European economic crisis, the presidential election, and

the fiscal cliff, but what will be the top issues facing the gear and bearing

industries in 2013? This year’s AGMA/ABMA annual meeting will

explore many of the topics impacting your company this year — from

new government regulations, economic challenges, and general industry

economic forecasts, to more detailed insight on potential new markets

for your business. The featured presenters at the 2013 annual meeting

are ready to give you the industry forecasts and market-intelligence you

need to succeed with best practices, data-driven insights, and trends in

the global marketplace.

Access to Industry ExecutivesThe most important aspect of the annual meeting is networking! Whether

you are new to the industry or have been involved for decades, the annual

meeting gives you access to hundreds of gear and bearing executives from

around the world. By meeting with your peers during the general sessions

at the golf course or over dinner, you will gain new insights into how

others are dealing with common problems facing the industry. Prepare

to develop new partnerships, or find that one new idea that makes your

company run more smoothly. Since hundreds of your peers will attend,

you can meet with your current partners and customers in just a few days,

saving your company multiple trips to visit each customer individually.

World-Class EntertainmentWe couldn’t ask for a better backdrop for the 2013 annual meeting —

sunny southern California.

Once home to Spanish missions, the area is now known for its sunny

warm weather, the Beach Boys, and a thriving community defined by

tourism, the defense, aerospace, and solar industries.

The Park Hyatt Aviara Resort is a first for the AGMA and ABMA

members as we venture into the warm coastal southern California sun

for our annual opportunity to network and bring home the latest “best

practices” from fellow gear and bearing industry executives. Between

the general sessions and networking events, you will have ample time

to explore the Carlsbad and San Diego area, home to world-class

entertainment, shopping, amusement parks, beaches, and precision

manufacturing.

For all these reasons, and many more, the AGMA/ABMA annual

meeting is the place to connect with international gear and bearing

industry executives. Don’t miss this opportunity to join your peers in

California for the ultimate networking event of 2013!

Complete information is available on the AGMA website at: www.agma.org

You Can’t Miss the 2013 Annual Meeting

22 gearsolutions.com

Norbert Benik: VP of Industrial Sales, Ontario Drive & Gear, Ltd.

Dean Burrows: President, Nixon Gear, Inc.

Sulaiman Jamal: Managing Director of Bevel Gears India Private Limited

Steve Janke: President, Brelie Gear Co., Inc.

Jan Klingelnberg: CEO, Klingelnberg Group

Tom Marino: President & CEO, Gear Technology

Mark Michaud: President, REM Surface Engineering

Gordon W. New: Managing Director, Ronson Gears Pty, Ltd.

Bob Sakuta: President, Delta Gear

Michael T. Smith: VP of Sales and Marketing, Capstan Atlantic

Michael E. Suter: VP of Marketing, Emerson Industrial Automation

Dirk Wernecke: Global Manager Pricing, Timken Company

AGMA leAdeRSHIP

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Matt Mondek: ChairmanPresident, Reliance Gear Corp

Louis W. Ertel, President & CEO, Overton Chicago Gear Corp.: Treasurer

John Strickland, VP of Marketing and Strategic Planning, Fairfield Manufacturing Co., Inc.: Chairman, BMEC

Dr. Phil Terry, Metallurgist, P. Terry & Associates: Chairman, TDEC

Dave Ballard, Director of Marketing & Business Development, Siemens Industry, Inc.: Chairman Emeritus

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Joe T. Franklin, Jr.: President

Charles Fisher: Vice President Technical Division

Jill Johnson: Director, Member Services

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1001 N. Fairfax Street | Suite 500 Alexandria, VA 22314

(703) 684-0211 | www.agma.org

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

After eight years of dedicated work, “IEC 61400-4, Wind Turbines – Part 4: Design Requirements for Wind Turbine Gearbox-es” was recently published.

The standard was developed through the efforts of members of ISO TC60 and IEC TC88 who came together in a Joint Work-ing Group (JWG) environment to discuss and debate issues that set this application apart as one of the most demanding on gear drive design and manufacture.

The AGMA Wind Turbine Gear Drive Committee was an active participant in this project, serving as the US Technical Advisory Group in developing positions on the many technical issues that were ad-dressed.

The Abstract of the Standard Reads:IEC 61400-4:2012(E) is applicable to en-closed speed increasing gearboxes for hori-zontal axis wind turbine drivetrains with a power rating in excess of 500 kW. This standard to wind turbines installed onshore or offshore. It standard provides guidance on the analysis of the wind turbine loads in relation to the design of the gear and gearbox elements. The gearing elements covered by this standard include such gears as spur, helical, or double helical and their combinations in parallel and epicyclic ar-rangements in the main power path. The standard is based on gearbox designs using rolling element bearings. Also included is

guidance on the engineering of shafts, shaft hub interfaces, bearings, and the gear case structure in the development of a fully inte-grated design that meets the rigorous oper-ating conditions. Lubrication of the trans-mission is covered, along with prototype and production testing. Finally, guidance is provided on the operation and mainte-nance of the gearbox.

IEC 61400-4 supersedes ISO 81400-4, which has been withdrawn. The current AGMA standard on this subject, ANSI/AGMA AWEA 6006-A03, Standard for Design and Specification of Gearboxes for Wind Turbines, continues to be an excel-lent resource for the wind turbine industry segment.

American Gear ManufacturersAssociation

New INTeRNATIONAl STANdARd fOR wINd TURBINe GeAR dRIveS PUBlISHed

24 gearsolutions.com

in the non-peened areas, leading to overcarburizing in topland and sides/corners. Peening is more useful after heat treatment than before. Also, theory says that a material with a higher Young’s modulus in the surface will have higher tensile stresses in the surface, about 30% for a thin layer (see figure 3). As the layer thickness increases, the stress amplification is reduced and the strength of the material increases. Effectively, there is a balance between the increased tensile stresses from bending and the increased strength of the material, but where the positive effects from densification outweigh the negative (in bending) is unknown.

So far we covered poroSity of powder metal and Some of itS effectS: Noise and NVH, macro design and reduced weight, and micro design and robustness. In this fifth article, we will discuss densification technologies.

First, I would like to stress that this article is based on my own findings and reflections. Having said that, let’s start with the basics. A sintered component has pores; these pores give the material unique properties — some good, some bad. One of the bad properties is lower fatigue strength in plane bending and contact. In the case of gears, the highest stresses are on the surface. Hertzian contacts will, in theory, have higher sub-surface stress than surface stress, may it be calculated as first principal shear stress or von Mise, but that is idealized and does not account for asperities, lubrication, wear effects, traces from manufacturing, etc. I read a quote from someone saying, “All models are wrong; some are useful.” Keep this in mind when discussing where high stresses occur in gears.

Since Young’s modulus is connected to density, a surface-densified material has a gradient in the Young’s modulus. This has implications as we will see below.

So if the pores are eliminated where the high stress occurs, the performance of the gears will improve. It then becomes a matter of how to remove the pores. There are several methods. Some of them are patented and have trade names (such as Densgrad or Densiform), some are free to use (such as peening), and some are in limbo (a few players seems to have patented the same technology). Let’s put the densification into the manufacturing chain: Compaction---Sintering---Densification---Heat treatment---Hard finishing.

The densification is done in the soft state, before heat treatment, and adds cost to the process.

Figure 1 shows a cylindrical roller that has been densified using rolling-type densification, basically a stiff gear burnishing machine (see figure 2). The specimens have been benchmarked in the ZF-type test rig and found to be slightly stronger than 8620 steel.

But for gears, it is a different, more complicated matter. In our next issue, we’ll look at the rolling-type densification processes with the “gear glasses” on.

Peening is the simplest process that may be used, and the equipment needed is the same as with regular steels. The obtainable layer thickness is up to 0.2mm. Drawbacks include a very dimpled surface that does not handle contact stress very well. Again, if the contact is handled as a Hertzian contact, all is well in theory, but in testing it will fail much sooner. When heat treating the peened gear, the carbon diffusion rate will be much higher

AbOuT ThE AuThOr: Anders Flodin earned his PhD on gear wear and failure modelling at the Royal Institute of Technology, Stockholm, Sweden, and continues to work in powder metal gear technology as a Höganäs AB employee in Sweden. Contact him at

anders.flodin@hoganas.com, or call +46 42 338906.

MATERIALSMATTER

Densification technologies in powder meal gears: If pores are eliminated where high stress occurs, gear performance will improve.

andersFLoDin Powder metal gear processes, Höganäs AB

Fig. 1: Roller for ZF 3 roller test rig, densified surface 1.3mm.

Fig. 2: Burnishing machine used for roll densification of gears.

Fig. 3: Stress amplification factor (κ)as function of relative densification depth (λ).

FEBRUARY 2013 25

The line of tangency between the pitch cones is the focus of all pitch points of the contracting gear teeth. At any specific point on this line of tangency between the pitch cones, the cone diameters will be directly proportional to the number of teeth. The tangent of the gear pitch-cone angle equals the number of gear teeth divided by the number of pinion teeth and the tangent of the pinion pitch-cone angle equals the number of pinion teeth divided by the number of gear teeth. The sum of the two angles in a 90º pair equals 90º.

MAnuFACturing MethoDs: Straight bevel gears are usually produced on special bevel gear generators. The choice of tooth forms is limited to those forms that can be most easily generated. They can also be produced by casting, forging, or milling. The teeth are cut by the generating process with rotary cutters. The tool travels across the face of the gear blank, which rolls when the teeth are generated. The rotary cutter is not as accurate as the generating process. To provide a high degree of finish, the gears can be lapped or ground — shaving is impractical. When the gears are to be lapped, the number of teeth in the pinion and mating gear should have no common factor.

Straight bevel teeth are cut on cones whose contours converge towards a point in the axis of the supporting shaft. The cutter used to generate straight bevel teeth is known as a basic crown rack. In both tooth thickness and tooth height, the teeth taper towards the inner end reducing the bearing surface and strength. The face width is also limited to one third of the cone distance. A greater face would result in an unacceptable small tooth size.

TOOTHTIPS

Straight bevel gears are usually produced on

special bevel gear generators. The choice of

tooth forms is limited to those forms that can be

most easily generated.

williamCrosherAuthor, engineer, and former director of the

National Conference on Power Transmission

William P. Crosher is former director of the National Conference on Power Transmission, as well as former chairman of the AGMA’s Marketing Council and Enclosed Drive Committee. He was resident engineer-North America for Thyssen Gear Works, and later at Flender Graffenstaden. He is author of the

book Design and Application of the Worm Gear.

AbOuT ThE AuThOr:

continuing our diScuSSion of bevel gearS, let's take a look at the design of the straight bevel tooth. In Figure 6-6, it can be seen that the curves are not generated by the pitch circle circumferences, but by curves C and the larger diameter C. The centers and radii are found by drawing lines B at a right angle to the pitch surfaces and meeting the shaft centers at D and D. A section through the tooth would show that the shape of the tooth is not in a plane parallel to the pitch cone. The teeth are located perpendicular to the conical pitch surface. The pitch angle is is the measure of the gear’s taper, and is defined by projecting the lines to meet at the cone center.

The pitch-cone pinion angle also equals its edge angle (Figure 6-7). The cone distance, or the dimension from the pitch cone apex to the pitch circle, is equal to the pitch diameter divided by two times the sine of the pitch-cone angle A in Figure 6-5. Straight bevel gears operate as two tangent cones rolling together without slippage.

Fig. 6-6: Straight Bevel Tooth Design.

Fig. 6-5.

Fig. 6-7: Pitch-Cone Angles – Pinion and Gear.

SPIRAL BEVELS

To Find Formula

Working Depth hk = 1.700 Pd

Whole Depth hk = 1.888 Pd

STRAIGHT BEVELS

Working Depth hk = 2.000 Pd

Whole Depth hk = 2.188 Pd

+0.002

26 gearsolutions.com

by the air instantly igniting the endo gas (hydrogen). The length of the flame would be proportional to the velocity of the air.

Problems can occur when combustible or fuel gas is used at temperatures below 1400ºF [760ºC]. This condition exists in many heat treating processes, gas nitriding being a very common one. It’s especially sensitive in integral quench batch furnaces (IQ) where many FNC [ferritic-nitrocarburizing] processes are performed. In these applications the hot zone connected to the quench vestibule is operating at approximately 1075º (579ºC) with a 50/50 endo/ammonia mix while the vestibule and quench tank with oil are cold. One of the mechanisms to prevent a premix from forming in either the hot zone or the vestibule a flame screen is incorporated at the bottom of the vestibule door. Upon charging a tray into the vestibule, the flame screen fills the vestibule with flue products and heat. When the door closes, one of two conditions take place: (1) adequate or excess fuel gas assures that 98% + of the oxygen within the vestibule has been consumed, or (2) inadequate fuel allows residual oxygen to remain possibly creating a situation that can cause a premix and ignition causing an impulse combustion (a burp) quickly pushing the door open. If we could see inside the vestibule after the door closes we would observe remnants of the fuel (flame) consuming the oxygen until the flame is gone; or without enough fuel the flame would extinguish quickly, leaving excess oxygen.

Getting back to the doors: Opening the doors of a furnace doesn’t present a problem – the closing speed does. In any furnace where endo gas is used, the internal pressure dictates how well the atmosphere will respond to control loop corrections. Pushers or IQ furnaces are designed to operate in a steady-state condition at approximately 0.1 to 0.3 inches of water column [WC] (0.25 mbar to 0.75 mbar) to function properly. When the inner door of an IQ furnace opens, the vestibule atmosphere is heated, rapidly increasing the pressure — the longer the door is open, the higher the pressure. Then when the inner door closes, the vestibule atmosphere rapidly cools and contracts, reducing the pressure in the entire system even the hot zone. Most maintenance problems in IQ furnaces are created when the inner door closes too fast, damaging the door and sucking in air to create an air/gas premix. When the inner door closing speed is reduced, the pressure reduction occurs gradually and to a lesser degree.

The flame screen and door concept can be observed at home: Place a lighted candle in a cereal bowl partially filled with water and place a glass over the candle. Sit back with the kids and watch!

if i’ve told you once i’ve told you a thouSand timeS: Close the door — and don’t slam it! That command, albeit in a different context, has been recited millions of times around the world by frustrated fathers and mothers...and by furnace engineers.

As manufactures of furnaces that operate with combustible gases for heating and hydrogen containing carburizing atmospheres, we are obligated to make sure that when a system is installed and commissioned all interested parties are trained in the proper operation. However, as a customer’s production resource requirements change, individuals come and go through the heat treat department, and more often than not the knowledge base is slowly diluted and inexperienced staffing results.

Then we get a call from a conference room populated with the plant manager, maintenance manager, maintenance supervisor, shift supervisor, safety director, heat treat supervisor, and finally the furnace operator. Through the mumbling in the background we would likely hear someone saying, “and that’s when the door came off,” or “that’s when we discovered the soft gears.”

Operating instructions for any device, whether it’s a household blender, dishwasher, or even a three-row carburizing furnace must comply with industry specific terminology, even though they are expected to be operated by people skilled in the art; but skill levels vary.

We’ve all learned at an early age not to stick our fingers into a light socket or run with scissors; what many may not have learned are the dangers of premixed natural gas and air and their undesirable potential to rapidly burn or, in some cases, explode. Our grandmothers faced similar problems with the old pilot ignited gas fired ovens and will attest to the trepidation of checking the condition of such pilots.

As furnaces go, when using combustible atmospheres any temperature above 1400ºF [760ºC] is a good thing, as that temperature is the auto-ignition point of the 10/1 air/gas ratio we use when firing into an alloy radiant tube. The same goes for the endothermic atmosphere. If, for example, a furnace with endo gas operating above 1400ºF [760ºC] and a pipe connected to the furnace was suddenly opened and air was introduced, you would see what I call a reverse flame: A flame created

HOTSEAT

As manufacturers of furnaces, we are obligated

to make sure that all parties involved with

installation are trained in the proper operating

procedures.

jacktitusDirector of process and developmental engineering, AFC-Holcroft

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.

AbOuT ThE AuThOr:

28 gearsolutions.com

By Tim Byrd

COMPANYPROFILE

“The challenges that we meet everyday well exceed what most engineers have to face. The rewards for meeting those challenges are terrific.”

RedViking Engineering

FEBRUARY 2013 29

RRedViking is a company with a passion for taking on the most difficult engineer-ing challenges. Its affiliate company, Superior Controls, located in Plymouth, MI, got its start in the systems integra-tions field, primarily automotive. But for the last 20 years, they’ve also been de-signing and building component test ma-chines. Two years ago, they took that end of the business and began RedViking, a group focused exclusively on building powertrain test machines. About that time, the company took on several large projects, including one for the Depart-ment of Defense. They center their at-tention on making “fewer moving parts.” President and CEO Randy Brodzik details their methodology:

“We are designing and building flexible test machines — flexible in that each machine is able to test a variety of trans-missions and gearboxes. We’re working on helicopter transmission and other powertrain test machines.

“When they approached us, our cus-tomer was working with a multitude of test cells, each with a cell that would test one particular transmission. This method is old-fashioned, impractical, and time-consuming, so they were look-ing to upgrade to newer controls and a much more stout machine. Our concept was to create flexible test machines that will allow them to test a whole range of transmissions on one single machine. We were able to take 21 test cells and reduce them to five, saving significant real estate, energy, and personnel at their location.”

The process rests on a concept that the main transmissions can all be tested on a single test machine. A helicopter typically has a main transmission that accepts power from one or more jet en-gines. RedViking analyzed the transmis-sions and gearboxes within the scope of work of their particular customer, and divided them into five different test ma-chines. So the challenge for each of the flexible test machines was to take the re-quired torques, speeds, and geometrical locations for the inputs and outputs. This required creating gearboxes with multiple inputs and outputs to test different com-ponents from different OEMs on a com-mon platform.

If you look at a helicopter in general, they typically have a main transmission that accepts power from one or more jet

engines. That power is then transmitted to the main rotor, which provides the lift for the helicopter. It also has an output that will typically go downstream towards the tail of the helicopter. There can be either a free wheel shaft or another in-termediate transmission that diverts that rotation up at an angle towards a

tail rotor. The tail rotor has another trans-mission to power itself. RedViking devel-oped machines to handle all the main transmissions, and other machines that would test the combination of the inter-mediate and tail rotor transmissions. The specifications weren’t exactly a piece of cake, either.

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“We had to live within the parameters of their test requirements,” says engineering manager Michael Schwartz. “They gave us a very specific set for each transmission. We verify all of our calculations. We have a very specific methodology that we use. The first step is to take the design parameters imposed on us by the customer (torque, speed, etc.). We go through a specific set of steps to establish our shafts and bearings for our design parameters, in order to stay within margins of safety and bearing life required to make a sound test machine.”

RedViking is growing. With 85 employees (equal to their affiliate company Superior Controls) and four locations in Plymouth, MI, Ra-leigh, NC, and Corpus Christi, TX, they are hiring “technical folks on electrical and design and mechanical side. It’s been difficult with the economic downturn that hit this area a few years back. Michigan lost a lot of talent. But all these prospective employees have to do is walk in the door, and their eyes light up. They see what we’re doing,” remarks Randy Brodzik.

“From an engineering standpoint, we get to work on the coolest machines on the planet. The challenges that we meet everyday well exceed what most engineers have to face. The rewards for meeting

those challenges are terrific. We’re dealing in horsepower that most engineers only dream about — almost unimaginable speeds up to 23,000 rpms, 10,000 hp in some machines. It’s exciting stuff.”

Drawing upon a wealth of practical knowledge and understanding within the aerospace, automotive, and defense industries to take on the most difficult problems in powertrain test machines, RedViking di-rector of marketing Brooke Elliott asks the pointed question, “Why are we the first ones to do this? Well, we dug our heels in and said, ‘Why not?’ We did that by equipping ourselves with some of the brightest minds we could find. We have a variety of experts from different fields on board, along with some of the brightest students coming out of school. We’re constantly trying to educate ourselves, and each other, and consequently we are growing as a group that will be the experts in the gear field.”

While they deal in serious horsepower, RedViking also knows how to lighten things up, with a strong emphasis on community. They have regular get-togethers, including chili cook-offs, an employee appre-ciation event that includes a remote-controlled helicopter obstacle course, and even a bake-off (lasagna won this year). The Toys for Tots program always generates a lot of participation, with hundreds of toys donated in December.

RedViking also supports the men and women of our armed forces, and their families, by supporting the Wounded Warriors program and by donating household items and furniture to military families through the Selfridge Air National Guard Base. In the tradition of “reduce, re-use, and recycle,” they’ve been devoted to developing energy-saving solutions since their inception. RedViking designs and builds systems with mechanical and electrical re-generation to maximize energy effi-ciency. Their largest transmission test system regenerates up to 80% of its energy, which can be used to power the system or be put back into the electrical grid. Additionally, there is a mindset of energy ef-ficiency within each office. “Internally, we are committed to recycling and minimizing our own carbon footprint,” says Elliott.

“The goal is to rebuild this level of experience. We want this coun-try to become world leaders in engineering again, and we think we’re doing our part. The people here are very proud of what they do, and they should be.”

TO lEArN mOrE: Visit www.redvikingeng.com or call 734-927-1460. The Control System Integrator Association (CSIA) is a global non-profit professional association for control system integration companies to advance system integration for the success of members and their clients. Visit www.controlsys.org.

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How to Minimize Downtime, Repair Costs, and Inventories by Extending the Life Expectancy of Your GearboxA commitment to maintain your gearbox is paramount for this to work economically. When you devise a plan to maintain your gearbox, your return on investment will be realized sooner and your total cost of ownership will be reduced.By Dan Rosseljong

JJUST LIKE TYPICAL CARS, GEARBOXES HAVE GOTTEN SMALLER OVER TIME. THE CATCH PHRASE

IS ‘POWER-DENSE’, MEANING THAT FROM EQUAL SIZED GEARBOXES, THE NEWER MODEL HAS A

MORE AVAILABLE RATING. DUE MOSTLY TO TECHNOLOGICAL ADVANCES, CURRENT MODEL GEAR-

BOXES WEIGH AN AVERAGE OF 25% LESS THAN THEIR 30 YEAR-OLD OLD COUNTERPART WHILE

DELIVERING THE SAME AMOUNT OF TORQUE, AND 35-40% LESS THAN THEIR 40 YEAR-OLD OLD

COUNTERPART. SINCE APPLICATIONS TYPICALLY DICTATE THE HP REQUIREMENT, THIS MEANS THAT

THE GEARBOX HAS GOTTEN SMALLER OVER TIME. A SMALLER GEARBOX MEANS THAT LESS OIL

AND SURFACE AREA IS AVAILABLE TO LUBRICATE AND COOL THE ROTATING ELEMENTS. BOTH OF

THESE ITEMS ARE PARAMOUNT TO THE LONG-TERM OPERATION OF A GEARBOX.

Small, power-dense gearboxes are often considered more economical than their older brethren. Because of their size, they require smaller foundations and structures to support them; use smaller quantities of lubricant to operate; and use less raw material to construct (and inevitably dispose of, which becomes more prevalent in our ever increasing “go-green” society). With this economical head-start it’s easy to think of many gearboxes as disposable or “throw-away.” Many people trying to justify why they don’t have or can’t make the time needed to properly maintain a gearbox claim, “It’s cheaper to buy a new one.” Don’t be fooled! It is easy for a plant to spend more money on repairing and replacing gearboxes in a few short years than to maintain one properly over the course of a many years.

We could spend countless hours pouring over a basic total cost of ownership (TCO) spreadsheet, researching wages, lost profit, lubrication costs, various fees, and service charges to name just a few of the costs. Each operation would then have to customize their own TCO spreadsheet to suit their particular process, only to support what common sense already tells us. Let us just agree on principle that it costs less to buy one gearbox in 10 years than five gearboxes for the same period. If you know that buying one new car and having it for 10 years is more economical than buying five new cars in 10 years, you should be able to see a correlation.

So what’s the purpose of this article, you ask? It’s not to convince you that you need to take care of your gearboxes; you already know that. What we are going to do is give you a few pointers and some ideas on HOW to properly maintain your gearboxes.

suMitoMo’s top ten List!Here are the top ten tips to keep your power transmission equipment operating at peak

performance; at highest efficiency; smooth and quiet; longer between repairs and rebuilds:

10. Ensure the gearbox is sized correctly to avoid inevitable repairs and costly replacements.

9. Store the unit properly according to manufacturer’s recommendations until it’s time to install, in order to avoid rust and dry rot.

8. Align the gearbox and components to the driven equipment to prevent excessive shaft or bearing loads.

7. Ensure the mounting sub-base is suitable for the weight and forces of the gearbox assembly to keep natural frequency vibrations from shortening the life of rotating parts.

6. Lubricant is a major contributing factor to the life of the gearbox.• Confirm the unit is filled with lubricant. • Fill the unit with the proper grade, type, and quantity

of lubricant if required, meeting manufacturer’s requirements.

5. Replace the lubricant according to manufacturer’s recommended intervals, including start-up periods. Pay close attention to units with oil in addition to grease requirements, e.g. oil lube gears and grease lube bearings, as they might be on different schedules.

4. Monitor the operation. The cooler the lubricant, the longer it will last!

- Keep the oil COOL – CLEAN – DRY. • Consider supplemental cooling from a water or air

cooler system.• Consider filtering if the environment is dusty or

humid.• Prevent water ingress to avoid rust.

- Data points and trend analysis to ‘predict’ concerns.• Oil analysis• Gearbox housing or oil temperature• Vibration

FEBRUARY 2013 33

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3. Inspections are required to confirm severity of trending issues. Plan for regular external [and internal] inspections, if the gearbox type allows. Raw data is good, but nothing beats seeing or feeling the parts first hand and understanding the condition of its severity.

2. Establish a preventative maintenance plan.

And the top item is…The Big Commitment

1. A commitment to maintaining your gearbox is paramount for it to work economically. When you devise and stick to a plan to maintain your gearbox, your ROI (return on investment) will be realized sooner and your TCO will be reduced. If possible, make it part of an ISO procedure to ‘force’ the implementation.

proper storAgeOk, you’re comfortable with the gearbox selection. One potential problem exists if it’s delivered ahead of the installation schedule. This also applies to critical spares for inventory. It’s the first offense many make: Protect your investment.

Unless the gearbox is going into installation and operation immediately, you’ll have to store it. If you have the option, store the gearbox inside. It will at least be protected from the elements. Most gearboxes shipped from reputable manufactures will ship the gearbox with some rust inhibitor

inside the unit and modifications for short-term exposure. We have seen gearboxes succumb to rust in under a week of exposure, so you need to use some common sense when determining what ‘short-term’ means to you.

The ideal conditions for storage are dry, low humidity, small temperature variances and non-corrosive atmospheres. When the temperature fluctuates greatly between daily highs and lows, condensation can build up inside the gearbox. If exposed to enough condensation build-up, the water will overpower the factory rust inhibitor. In response you might say, “So fill up the gearbox completely with oil!”

Yes, metal submerged in oil will not oxidize. In some cases, that’s the best option. In other cases, it’s the only option. In a few cases, you’ll negatively affect the gearbox’s operating performance (and maybe not even know it). With every action comes a trade-off. For smaller gearboxes this typically won’t be a problem. The best argument against completely filling large units with oil is that the standard oil seals may not be designed to have such a large head of oil behind them. Contrary to popular belief, most seals are only capable of handling a few PSI’s of pressure. The amount of oil required to generate enough PSI varies depending on the size and orientation of the gearbox. Temperature can also affect the pressure of the oil. As a unit full of oil bakes in the sun, the heated oil will want to expand. In certain instances, only a few gallons of oil provide enough weight to weep oil through the

36 gearsolutions.com

seals. The issue is scalable. Larger units required more oil. So you have a large unit that costs a lot of money and

because you don’t have the indoor space for it, you store it outside and probably out-of-mind. Units are usually stored outside because of limited space or outdoor projects. The units probably won’t be looked at as part of a general preventive maintenance procedure, so as the unit weeps oil you have a) an environmental problem and b) air backfilling the gearbox. This air condenses, and we’re back to the problem addressed earlier, and you now have an oil spill to clean up.

Consider a temporary structure or “lean-to” in order to protect your investment from the elements. Follow the gearbox manufacturer’s recommendations for storage and the schedule for reapplying rust preventative.

is there reALLy suCh A thing As A quiCk stArt guiDe?Installation starts by securing the gearbox firmly to a rigid foundation if floor-mounted, or securing it to the shaft for shaft-mounted installations. Follow the gearbox manufacturer’s recommendation for mounting bolt grade or strength and use all of the available mounting points. If mounting to a structure, your structure must be capable of supporting the weight of the gearbox assembly and oil without

deflection. If there is deflection in the mounting structure, it must not exceed the allowable limits of the shaft connections. Couplings, chain and sprocket, or V-belts and sheaves typically make shaft connections. Each of these shaft connections has their own recommended alignment tolerances.

Not all gearboxes are equivalent — some will have different installation parameters. It’s important to read and understand the complete manufacturer’s maintenance manual for your equipment. Sometimes there might even be different manuals if you are installing different product models. For example, the mounting surface needs to be level to within tenths of a degree on some gearboxes.

After the gearbox is level according to specifications, alignment of the motors, chains, and v-belts are the next critical item on your new checklist. Shaft connections need to be as accurate in parallel and angular alignment as possible. Depending on your installation configuration, it is strongly suggested to fix one component and align all other components to it. If you are installing separate motor and gearbox components, align the gearbox to the driven shaft of your equipment, and then align the motor to the gearbox. If you are installing a completed bedplate assembly from Sumitomo, the gearbox is mounted to the bedplate and motors and couplings are aligned to it. This allows the entire bedplate to be aligned to the driven equipment.

FEBRUARY 2013 37

trenDing is the key...The external critical items to monitor on a normal gearbox application would be 1) temperature, 2) vibration, and 3) noise. An increase of any (or all) of these is a significant signal that something is wrong. We are talking about even the beginning stages of a wearing item, not necessarily an immanent catastrophic event. Gear or bearing wear can progress for months or years depending on the speed, load condition, and lubrication.

These external ‘signals’ are indicators of the operating condition of internal components. The gears, bearings, seals, and lubrication are often trying to ‘say’ something to the operator. A temperature rise can be caused by any of the elements of a gearbox. Noise can also be generated from all of the elements of the gearbox. Noise can also be caused by vibration. Vibration can be caused by all of the elements in

the gearbox. There is no single cause and effect critical path when it comes to the signals being put out by the internal components. This is where a bit of experience and “CSI” methodology require operators to determine root-cause problems. All reputable gearbox manufactures will have personnel at the factory or local warehouse who can offer technical assistance.

The main root cause of bearings, gears, and oil degredation are typically:

a) overload operating conditions (too much throughput or E-stops)

b) improper oil viscosity c) oil cleanliness (dusty, dirty or wet

environments? Your last oil change was when?)

d) oil temperature

There are a number of ways to combat the monitoring of various gearbox

components. Trending these items is the key. If we assume that the plant is responsible for overload conditions imposed on the gearbox and these are minimized, we can focus on actually monitoring the gearbox.

LubriCAtionLubrication is the lifeblood of a gearbox. You want to keep the oil clean, cool, and dry.

Just as you would never run your car without oil, so it is the same for the gearbox. Sounds simple! Make sure the gearbox is filled to the proper level with the proper lubricant. Some gearboxes come factory filled. In this case, visual inspections are required to ensure no leaks develop. For many other cases, the lubricant type and quantity is the responsibility of maintenance personnel. Check the gearbox operating and maintenance (or Installation)

38 gearsolutions.com

manual for the proper grade of lubricant. Sometimes this will also be on the nameplate. Usually different ambient temperatures require different lubrications, so be aware of outdoor operations that span winter and summer seasons. Lower temperatures require thinner oil to flow effectively and conversely thicker oil for higher temperatures to compensate for heat breakdown. Check the gearbox for the actual oil fill level. Most operating manuals list approximate oil quantities. Always fill the gearbox to the level indicated by a sight gauge, dipstick, or fill level plug.

In a perfect world, properly selected lubricant will protect all the compents The reality is that all manufactured components will have some normal wear. These normal wear metal particulates have to go somewhere, and into the oil bath or lube system they go! Left alone, these particles will act as abrasives and further wear the gearbox or lube system components until an inevitable failure. This is why most gearbox manufactures recommend an initial oil change somewhere in the first 500 hours (or six months of operation). Grease-filled units don’t often have the same change requirements, since the grease has a tendency to suspend the particles rather than splash them around the gearbox and into critical components.

VisCosityThis is magical to some people, but there is a science behind it. Automobile manufactures typically recommend between a 3000 to 5000 mile oil change interval depending on the type of driving you do. To be more specific, this is an average life span of the oil viscosity. Automobile manufacturers base this estimate on countless hours of raw testing and it means we are changing oil on a convenience schedule instead of when it is actually required.

During operation, the oil will cycle through the various components. At each load point on the gears and bearings, the oil is put under extreme pressure. The oil is designed to absorb this extreme pressure, by providing a thin film of lubricant, but not infinitely. After an estimated time period, our experience indicates that the oil will start to lose its ability to provide adequate protection against pressure. Inadequate viscosity can lead to scuffing which creates wear particles. Wear particles only lead to more wear. Too high of a viscosity leads to ‘skidding’ which generates heat. Too low of a viscosity leads to ‘flow’ problems (or inadequate lubrication during splash) generating more heat. Theoretically, if you maintain the proper grade of oil, the gears and bearings should last for a very long time. There are a few exceptions to the rule and sometimes a multipronged approach is best. In our experience, maintaining the oil quality is the first priority.

Your first option to protect against viscosity breakdown is to change the oil at the designated intervals, per manufacturer’s instructions. This option, while convenient, may have you throwing away ‘good’ oil. Arguably the next best option is to determine the oil viscosity and trend it through oil sampling and testing (also known as tribology). There are many labs

across the country that specialize in testing oil. Chances are your lubricant supplier can do it or recommend someone. All major lubricant manufacturers have some testing capabilities and strongly recommend this option to predict your oil life span. After only a few tests you will be able to accurately predict the oil change interval for your gearbox. If any problems do develop with the gearbox and it is returned to the manufacturer, you’ll have the proper documentation to illustrate when and why you changed the oil – despite the operating manual recommendations. If you have complete records, I predict that the gearbox manufacturer will be more interested in the condition of the oil over time, then whether or not you followed the operating manual to the letter. How can they argue against using the proper viscosity of oil? Just be sure to maintain your records – or you won’t have a ‘leg-to-stand-on’ when they inevitably question you about your oil changes! Sumitomo engineers will consider your accurate laboratory records during a warranty evaluation without penalizing you for changing the oil before the oil goes bad, not just during the maintenance manual schedule.

CLeAnLiness is next to goDLiness...Particulates in the oil are a close second problematic area after viscosity breakdown. As your car has an oil filter, sometimes your gearbox should too. A magnetic drain plug is low end technolog, and used in conjunction with other methods, is an inexpensive and relatively effective method of keeping metallic wear particles out of rotating elements. If your gearbox is forced-lubricated (through a shaft or motor driven pump), always make sure the lubricant is filtered. If you have an extreme environment, like severe dust or dirt, consider adding a circulation pump and filtering the oil. On larger units where breathers are required, filtered breathers for dusty and dirty environments help. Most breathers require some form of regular maintenance to ensure they are not clogged, or that the desiccant is still active. A clogged breather will pressurize the gearbox and the path of least resistance is usually the seals. So if your gearbox is weeping oil at the seal, check to ensure the breather is not clogged before scheduling a rebuild. Additionally, gearboxes buried in dirt, coal, or dust do not transfer heat as effectively as a clean gearbox. Keep the housing surface clean to avoid oil contamination and heat buildup.

keeping it CooL...Heat is a natural component of all mechanical devices. It’s this heat that helps to break the oil down. Once the oil starts to break down it usually is a very fast decline to ‘worn’ oil. This ultimately leads to metal-to-metal contact. Some experts would recommend trending this temperature rise. When you trend the temperature of the gearbox, the idea being able to determine if ‘something’ is going wrong with the gearbox. Unfortunately, a rise in temperature can be, among other things, a bearing going bad or from ‘worn’ oil. Ultimately you

FEBRUARY 2013 39

are left to determine the cause of the temperature rise. While this is a relatively inexpensive up-front alternative, it usually leads to more questions.

Heat will break down the viscosity of the oil, preventing it from properly lubricating the gearbox components. You can keep the oil cool in a number of ways. Usually the most common and cost effective is to keep the gearbox within its thermal limitations. All gearboxes have a thermal rating. For some units, thermal rating is not a problem; it may exceed the mechanical rating by design (like most Sumitomo Cyclo Drives) or because high reduction ratios (above 90:1) correlate to more gears and bigger housings. For units with gear teeth, like worm or hardened and ground helical or bevel gearing, as the unit ratio gets smaller the unit is more thermally limited. Simply put, this has to do with surface area. The more surface area, the more heat transfer (convection) can occur.

The Torque-HP-RPM formula says that for constant torque (like a gear), Hp will vary with speed. Therfore high speed equates to high horsepower. The lower the ratio, the faster the gearbox, and the higher the HP capacity for an equivalent-sized gearbox. Lower ratios are typically 1, 2, or 3-stage units with high mechanical Hp ratings but a relatively small housing surface area. These units can be boosted thermally by an economical shaft driven fan that in many cases is a standard option. For units where the fan doesn’t provide enough boost, you should consider a separate cooling system. This is similar in principle to your car cooling

system, except the oil is pumped in directly through a radiator and cooler oil is returned back to the gearbox. Gearbox radiators or heat exchangers can be oil-to-water or oil-to-air coolers. Oil-to-air is just like your car radiator. The oil-to-water uses plant water to more effectively transfer heat.

keeping it DryEveryone knows that oil and water don’t mix. Besides interfering with the proper lubrication of the rolling elements, metal corrosion can be a problem. Corrosion will lead to particulates. For outdoor or humid environments, there are a couple of tricks to slow down water ingress into a gearbox. It sounds weird, but an immersion oil heater (usually used to keep oil warm in cold weather starts) can keep the oil at a constant temperature between day and evening temperature swings where condensation might be a problem. For a unit running 24/7, condensation might not be an issue, since the gearbox is at a relatively constant temperature. For units that only shut down for periods of time, like second and third shifts, condensation build-up might be an issue for you. An immersion oil heater can help.

Another method is to install a hydroscopic breather. These breathers are filled with desiccant to absorb moisture. Some hydroscopic breathers come with plugs to allow air to filter through the desiccant. In a humid environment, it’s imperative to only remove one or two plugs (typically) so that the breather isn’t trying to absorb moisture from the atmosphere, which can lead to shortened breather life.

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stAte inspeCtion now DueIf you have scheduled outages, you need to plan and execute an inspection of critical equipment like gearboxes. Just like your car is (supposed) to be inspected once a year to maintain a minimum safety standard for operation, your plant equipment should be inspected to identify items that should be closely monitored, so that they can operate effectively until the potential problem is rectified. An external visual inspection should indentify proper oil level, signs of leakage, or cleanliness. An internal inspection is even more important and should be scheduled on a regular basis. Internal inspections should identify the surface condition of the components and any abnormal wear.

If you’re operating 24/7, internal inspections are not practical. In these cases, alternative monitoring equipment should be considered to trend the operation of the gearbox. Vibration accelerometers are a common example. If you are able to monitor each bearing, you’ll likely be able to pinpoint the actual element in question (i.e. bearing or gear) due to operating frequency of that particular component. There are many third party companies that specialize in this type of monitoring — consider this alternative if you don’t have the staff to monitor and evaluate frequency calculations. They have the software and focused expertise to evaluate the gearbox effectively. In most cases, they will even contact the manufacturer for all the gear tooth counts and bearing

numbers, which are required to identify the frequencies based on operating speeds.

the big “C” in tCoA commitment to maintain your gearbox is paramount for this to work economically. When you devise a plan to maintain your gearbox, your ROI (return on investment) will be realized sooner and your TCO (total cost of ownership) will be reduced, if you stick to the plan.

Keeping the oil in proper condition will by far ensure a properly sized and operating gearbox, running longer, reduce your repair costs and ultimately reduce your inventory for spare parts.

ADDitionAL sourCes:Fred Mitchell, Sr. equipment builder engineer, ExxonMobil Jeff Rybak, field application engineer, PCB PiezotronicsJoe Medici, account manager, Bently Tribology Services.

AbOuT ThE AuThOr:

Dan Rosseljong is chief product engineer of Sumitomo

Machinery Corporation of America. For more information,

visit www.Sumitomocorp.co/english.

CLIENT: Kaydon

AD SIZE: 7.75” X 4.875”

INSERTION #: HI-4102

PUBLICATION: Gear Solutions

DATE: Jan Issue (out late Dec)

CONTACT: Chad Morrison

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Two Case Studies in the Mining Industry with the KISSsoft Gearbox Variant GeneratorWhen designing gears, the size, weight, and manufacturing cost can be influenced to a great extent by both strategically splitting the overall reduction over the individual stages and by optimizing the geometric relationships.

By Dr. Ing. U. Kissling

WWHEN DESIGNING GEARS, THE SIZE, WEIGHT, AND MANUFACTURING COST CAN BE INFLUENCED TO A GREAT EXTENT BY BOTH STRATEGICALLY SPLITTING THE OVERALL REDUCTION OVER THE INDIVIDUAL STAGES AND BY OPTIMIZING THE GEOMETRIC RELATIONSHIPS. A NEWLY DEVELOPED TOOL, THE KISSSOFT GEARBOX VARIANT GENERATOR, IS ABLE TO AUTOMATICALLY GENERATE DIFFERENT GEAR VARIANTS, ALL OF WHICH HAVE THE SAME TOTAL REDUCTION AND PERFORMANCE, BUT HAVE DIFFERENT NUMBERS OF STAGES AND DISTRIBUTION OF REDUCTION ACROSS THESE STAGES. IN ADDITION, THE GENERATOR SYSTEMATICALLY VARIES DESIGN PARAMETERS THAT ARE KNOWN TO HAVE A FUNDAMENTAL INFLUENCE ON GEAR SIZE. THESE DIFFERENT DRIVE VARIANTS ARE ALL SIZED EXACTLY WITH GEARS, SHAFTS, AND BEARINGS THAT SUIT THE TORQUE TO BE TRANSFERRED. EACH OF THESE DIFFERENT SOLUTIONS IS NUMBERED SEQUENTIALLY AND DISPLAYED AS A 3D DIAGRAM TO MAKE THE BEST SOLUTIONS EASY TO IDENTIFY.

THE FIRST TWO CASE STUDIES, WHICH USED THE GEARBOX VARIANT GENERATOR TO ANALYZE AND OPTIMIZE GEARS, ARE DETAILED BELOW. BOTH CASES INVOLVE GEAR UNITS USED IN THE MINING INDUSTRY: ONE WITH 12 MW NOMINAL POWER AND THE SECOND WITH 200 KW NOMINAL POWER. THE STUDY REVEALED THE QUITE ASTOUNDING POTENTIAL FOR SAVING BOTH WEIGHT AND COSTS.

surFACe Mining geAr units FroM A MAnuFACturer in the usAIn the USA, large gear units traditionally use double helical gearings made of heat-treated steel (without surface hardening). These gear units are therefore larger and heavier than those made from case-hardened steel. However, because no hardening and grinding processes are involved, the manufacturing costs (in $/kg) are very low. The case study concerns the cable drum drive used in a gigantic dragline (Figure 1) manufactured by the company Bucyrus International, Inc. The drum has a diameter of 3.5 m and is driven by eight motors (four on each side), each with 20.5 kNm torque. The four motors on each side are connected to each other by two reduction stages. A slower stage output gear is mounted on each side of the drum. This is driven by two pinions. Each of these pinions is in turn connected to the output gear of an input stage, each of which is driven by two motor pinions (Figure 2). An overall reduction of 35.5 results in a torque of 5.8 MNm (12.7 MW) on the drum. A picture of the drive configuration is shown in Figure 3.

In this analysis, only one drive train consisting of one motor with input and output stages will be considered. There is no real point in modifying the variant generator to the effective, less common drive configuration because it is possible to correctly reproduce the influence of the other motors in the calculation without any additional effort. Because the output gear on the input stage drives two pinions, it is simply a case of doubling the number of load cycles of the output gear. Furthermore, as

the output stage pinion transfers double the amount of power, the application factor of the output stage, KA, is also doubled. Finally, to take the different numbers of individual parts into consideration when calculating the total weight and the manufacturing cost, the specific weight is also doubled or quadrupled accordingly. With these modifications, the existing 4-motor drive design can be represented as accurately and realistically as possible.

In the first step, the current state of the drive unit is analyzed to determine its current strength. The bearing service life and the gearing safeties (bending and pitting) are of particular interest in this context. The purpose of this analysis is to define the safeties obtained from the mathematically weakest part. These define the minimum safeties for the drive variants that will then be sized.

The results of the analysis of the actual situation are given in Table 1. Here the weight was calculated using the same method as was used later to calculate the variants. The manufacturing costs

Fig. 1 (Left) : Surface mining dragline with the drives used in the analysis (photo BUCYRUS®, USA).

Fig. 2: Machinery diagram.

FEBRUARY 2013 43

shown here were each determined as $/kg prices using data provided by the manufacturer. This examination takes into account the costs for shafts, pinion shafts, gears and housing. Costs for the roller bearings have been omitted, because bearings of this size are not commonly available and no standard prices could be found for them.

As requested by the customer, the variant analysis was performed with only two stages, although for an overall reduction of 35.5, a 3 stage variant would be well worth considering. The input stage reduction was varied in 10 steps:

from 5.00 to 13.16 (and the drive correspondingly from 7.09 to 2.70). In addition, the program counted upwards from 0.15 to 0.40 in increments of 0.05 for each ratio variant. As a result, it calculated a total of 70 gear units.

Figure 4 shows the gear housing dimensions of the different variants. They vary greatly in length, from 5300 to 7500 mm on the X axis, from 1030 to 2100 mm on the Y axis, and from 3280 to 5600 mm on the Z axis. Of even greater interest is the overall weight and manufacturing costs shown in Figure 3. The least heavy variants are those with i2=5.1 and with b/a=0.3. Those with the lowest manufacturing costs have i2=4.6 with b/a=0.25. The Figure clearly illustrates that the costs as a function of i2 and b/a show a fairly flat minimum, which varies within the range i2= 4.1 to 5.2 and b/a= 0.23 to 0.32.

Comparing the least expensive variant (Table 2) with the status quo shows that costs could be reduced by 22%. Furthermore, the existing variant has a reduction distribution (i2=3.8), which lies below the optimum range, whereas the b/a values lie within the optimum range. In contrast, the existing variant does not have the best possible distribution of gear safeties. The output stage displays significantly higher safeties than the drive stages. This analysis shows that the current gear unit has been very well designed. When considering the considerable cost differences between the individual variants (Figure 5) the actual costs still lie within

Fig. 3: Drive configuration.

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reasonable bounds. However, there is no question that a possible saving of over $100,000 is well worthwhile.

geAring proDuCeD with hArDeneD MAteriALsIt is well worth investigating whether a more cost effective solution could be achieved by using surface hardened materials. This would possibly involve the practical option of manufacturing the pinion shafts from case-hardened and ground steel, and the gears from heat treated (milled and nitrided) steel. The Gearbox Variant Generator can perform this type of analysis very quickly once the manufacturing costs are known. As a rough starting point for this analysis, we increased the costs for the pinion shafts (ground) by 100% and those for the gears (nitrided) by 50%.

For experts, the results bring no surprises: In this variant, the weight of the gear unit can be reduced by 50%. According to the cost calculation the result is a reduction of 37.5%, or 20% in the case of the optimized gear unit made of heat treated steel (Table 2). In this context it should be noted that the assumed cost rates for this last analysis were estimated approximately and would need to be defined in more detail.

Mining geAr units FroM A gerMAn MAnuFACturerThe second case study involves a medium-sized gear unit (200 kW) manufactured by Bucyrus Europe GmbH

Table 2: Most important results for the optimum variant.

Fig. 4: Housing dimensions (X, Y, Z) of the different variants.

Table 1: Most important results of the analysis of the actual situation.* Facewidth b: Total width of the gear including intermediate groove (double helical gearing)

Table 3: Data for the optimum variant when surface-hardened materials are used.

46 gearsolutions.com

for use in the mining industry and with a traditional European industrial gear box design. All the gears are made of case-hardened steel and the drive stage is ground. The procedure for the analysis was carried out as shown in the example: The results of the analysis of the actual situation (where the variant was calculated with two stages) are shown in Table 4. The reduction of the drive stage was varied in 9 steps – from 1.20 to 3.4 (and the

drive correspondingly from 6.00 to 2.2). In addition, b/a was varied from 0.10 to 0.90 in increments of 0.20 for each ratio variant. A total of 45 gear units were calculated. Manufacturing costs were defined using EUR/kg pricing data provided by the manufacturer.

The results of the optimization process are shown in the figures that follow. It is obvious that there were significant differences in the external dimensions (Figure 6). This result from

the Gearbox Variant Generator can be extremely useful if the new gear has to be installed in a specific space. The total weight and manufacturing costs displayed depending on b/a and i2 (Figure 7) also clearly illustrate that this design example – where the output stage is not ground – gives the optimum drive variants for b/a=0.3. The optimum b/a ratio is relatively small because, due to the nonground output stage, the face load factor KHb would increase

Fig. 6: Housing dimensions (X, Y, Z) of the different variants.

Fig. 5: Weight and manufacturing costs depending on output stage reduction (i2) and the width/center distance ratio (b/a).

FEBRUARY 2013 47

significantly as the width increases and would therefore make this variant uneconomical. The ratio distribution between the stages gives good results if the output stage has a reduction in the range 2.0 to 3.0.

A second calculation run was performed to analyze the optimum

range of solutions in greater detail: The reduction of the drive stage was varied in five steps from 1.81 to 3.0 (and the drive correspondingly from 4.11 to 2.48). In this instance, b/a was increased for each ratio variant from 0.18 to 0.42 in increments of 0.04. This analysis calculated a total of 35

gear units whose results are shown in Figure 8.

Contrary to expectations, the second run did not find a significantly better solution. The best solution with regard to weight was found in the first calculation run at b/a=0.3 and i2=3.64, which gave a weight of 1077 kg. In the second run, the optimum weight at b/a=0.26 and i2=2.82 was 1073 kg. The differences in manufacturing costs were also not very great. In the second run they were only reduced from EUR 18360 to EUR 18302, a reduction of only 0.3%. The range that contains drive variants with minimum costs is obviously scarcely affected by smaller changes to the output reduction or the b/a ratio. This situation is also very obvious in Figure 6. It is beneficial to recognize this fact, which can then be applied if it is intended to create different reduction systems in the same gear housing, while keeping costs down.

Comparing the least expensive variant (Table 5) with the status quo shows

Table 4: Most important results of the analysis of the actual situation.

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that costs could be reduced by 20%. The actual variant has a reduction distribution which almost lies in the optimum range, whereas the b/a values lie a little above it. In our opinion, the current gear unit has been fairly very well designed, even if a possible saving of 20% could be achieved, and should therefore be taken into consideration.

ConCLusions Two very different gear unit variants from mining applications were investigated with the Gearbox Variant Generator. In both cases, an analysis of the status quo was performed, to determine the effective strength values and safety factors for the gear units. Then, a large number of gear units with the same strength values, but with differing reduction distribution due to different

stages and b/a parameter, were designed.

In both cases the study showed that the gear units were definitely well designed for their intended purpose: Compared to the range of possible solutions, the current actual design lies in the "green" 9 zone. Nevertheless, the study showed that, in both cases, costs could be reduced by 20% if the best possible solution were adopted. In both cases, KISSsoft's Gearbox Variant Generator has proved its effectiveness: Without this tool it would have been impossible to perform these studies so quickly, even with the most sophisticated software.

reFerenCes[1]: Kissling, U.: Optimierungsprozedur

zum Auslegen von Stirnradgetrieben

nach Gewicht, Kosten und W i r kungsg r ad , Ze i t s ch r i f t ‚Konstruktion‘, 2011, Heft 3.

[2]: Kissling, U; Kivelä, R.: Automatic Optimization Procedure of a complete Gearbox for weight, ef f iciency, costs and dimensional restrictions; International Conference on Gears; VDI Bericht 2108.2; 2010; ISBN 978-3-18-092108-2.

AbOuT ThE AuThOr:

Dr. Ulrich Kissling, ING. is the

president of KISSsoft AG in

Hombrechtickon, Switzerland.

Contact him at +41 55 254 20 50

or visit www.KISSsoft.AG.

Fig. 7: Weight and manufacturing cost (EUR) depending on the reduction of the output stage (i2) and of the width/center distance (b/a) ratio.

Table 5: Most important results for the optimum variant.

Fig. 8: Weight and manufacturing cost (EUR) after more detailed breakdown of the reduction interval and the b/a interval.

FEBRUARY 2013 49

Crack Testing and Heat Treat Verification of Gears Using Eddy Current TechnologyEddy current testing offers fast, repeatable testing of gears and other critical metal components, a feature required in today’s modern manufacturing environment.

By Dan DeVries

WWHILE EDDY CURRENT TECHNOLOGY WAS INITIALLY DEVELOPED FOR TESTING OF BAR, TUBE, AND WIRE, ADVANCES IN ELECTRONICS, AUTOMATION, AND COIL DESIGN HAVE PAVED THE WAY FOR A NEW GENERATION OF SYSTEMS SPECIFICALLY DESIGNED TO TEST CRITICAL COMPONENTS, SUCH AS GEARS, THAT GO INTO AUTOMOTIVE AND INDUSTRIAL APPLICATIONS. THESE EDDY CURRENT TEST SYSTEMS NOT ONLY DETECT CRACKS IN COMPONENTS, BUT ALSO VERIFY PROPER HEAT-TREAT CONDITIONS, PROPER ALLOY COMPOSITION OR MATERIAL STRUCTURE, AND THE PRESENCE OR ABSENCE OF FEATURES SUCH AS SPLINES OR TEETH.

EDDY CURRENT SYSTEMS ARE FAST, CLEAN, REPEATABLE, AND EASY TO INTEGRATE INTO PRODUCTION PROCESSES ALLOWING FOR IN-LINE TESTING AT PRODUCTION LINE SPEEDS. IN ADDITION TO ENABLING 100% OF PRODUCTION COMPONENTS TO BE INSPECTED, EDDY CURRENT TESTING HELPS TO MONITOR UPSTREAM PROCESSES NOTIFYING OPERATORS THAT SOMETHING IS NOT FUNCTIONING CORRECTLY ON THE PRODUCTION LINE. THIS GREATLY REDUCES SCRAP AND WARRANTY COSTS FOR GEAR MANUFACTURERS.

Eddy current testing is often used to replace chemical testing processes such as dye penetrant and magnetic particle inspection for crack testing, and cutting and acid etch testing to verify proper heat treat patterns. These chemical tests are typically performed off-line after a production batch has been run and is subject to operator skill and error. In the case of cutting and acid etch testing, the part is destroyed. Eliminating or reducing off-line chemical testing allows companies to reduce the cost of chemical purchases, reduces hazardous wastes, and allows companies to "go green."

eDDy Current 101Eddy current testing is an electromagnetic, non-destructive testing method that measures the flow of eddy currents in a conductive material. Changes in the material due to cracks or “structure” changes, such as heat treatment or alloy variation, cause the eddy currents in the material to flow differently. This difference is detected by an eddy current instrument.

Figure 1 shows how eddy currents are generated and flow in a test scenario. An AC signal generator drives an electrical current through an eddy current coil, generating a magnetic field around the coil. As the coil is held in close proximity to the component under test, the magnetic field induces eddy currents to flow in the component. These eddy currents, which change their flow around cracks or flow differently in different alloys or heat treat conditions, create their own magnetic field which is then sensed by the same coil or by a different coil.

Figure 2 shows a block diagram of an eddy current test system. A signal generator in the real-time signal processing block sends a single frequency or multiple

Printed with permission of the copyright holder, the American Gear Manufacturers Association, 1001 N. Fairfax Street, Suite 500, Alexandria, Virginia 22314. Statements presented in this paper are those of the authors and may not represent the position or opinion of the AMERICAN GEAR MANUFACTURERS ASSOCIATION.

Figure 1: Eddy Current Flows.

Figure 2: Block Diagram of an Eddy Current Testing System.

Figure 3: Cracks in Carrier Gear Assembly.

FEBRUARY 2013 51

frequencies through a digital-to-analog converter (D/A) out to a single coil or multiple coils where magnetic fields are generated. The eddy current signals are measured by the same coils or different set of coils and are digitized by an analog-to-digital converter (A/D). The real-time signal processing electronics compare the returned

signals with the sent signals and determine whether an “alarm condition” has occurred. If an alarm condition has occurred, a signal is sent to a programmable logic controller (PLC) within a material handling station to reject the part from the assembly line. Testing data can be sent to the factory MES or quality systems to track trends and store data. This

data can be stored on-premise or in the cloud. Modern touch panel displays greatly simplify user interfaces and allow operators flexibility in setting up their production lines.

CrACk testingEddy current crack testing is performed by passing a pair of coil windings over a section

Figure 4: Carrier Gear Assembly Eddy Current Probe Fixture. Figure 5: Eddy Current Probe and Heat Treated Internal Gear.

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of the component to be tested. These coil windings can be made small enough to test between gear teeth, and with multi-coil probes can test very complex shapes. Most crack test applications use one test frequency, as they only require detection of surface flaws. Typical test frequencies range between 10 KHz and 4 MHz with higher frequencies used to find

smaller surface flaws. Simultaneous testing with multiple frequencies allows for testing of both surface and sub-surface defects when inspecting non-ferromagnetic parts.

An easy-to-see crack test application is shown in Figure 3. In this case, the carrier gear experienced cracking upon assembly. The probe assembly shown in Figure 4 was used

to detect the flaws. This probe uses multiple coil assemblies (the white blocks) so that the testing fixture did not have to rotate 360 degrees for testing. This made for a simpler material handling station.

heAt treAt VeriFiCAtionWhile not an absolute hardness test like a

Figure 6: Complex Heat Treat Pattern on Wheel Spindle Bearing. Figure 7: Wheel Spindle Eddy Current Harness Probe.

FEBRUARY 2013 53

Rockwell test, eddy current heat treat verification can achieve sorting results on par with Rockwell testing. This has been demonstrated with both forged and powder metal gears. Eddy current heat treat inspection coils come in both standard encircling coil configurations and multi-coil custom configurations. The custom configurations allow for precise location testing verifying that induction heating parameters were correctly applied. Defects to be tested include misplaced case, shallow case, short quench, delayed quench, air cooled, non-heat-treat, and ground out conditions.

When performing heat-treat inspection, multiple test frequencies are used to reliably detect these various heat treat anomalies. A range of eight frequencies is commonly used with the ratio of the lowest to highest frequency of 1:1000 or more. Structure defects or anomalies are usually discoverable within those frequency ranges. Using an eight frequency test also makes setting up a test much easier.

Figure 5 shows a heat treated reaction internal gear that needed to be heat treat tested. On the left hand side is the custom designed eddy current probe used to test

the gear. The two eddy current coil windings are clearly seen as bands in the white nylon housing. Two areas on the gear were tested using this set up.

Figure 6 shows a good example of a complex heat treat pattern in a cut away wheel spindle bearing sample. This sample was prepared using an acid etch process and clearly shows the heat treat pattern. The probe used to test the bearing is shown in Figure 7 and has four individual coils to verify proper placement and depth of heat treat at various locations on the part. The visible coil winding seen on the bottom of the probe inspects the bottom flange area for proper run-out. The metal components of the probe are made of stainless steel to increase the longevity of the probe.

Figure 8 shows a detail of the material handling station used to test the wheel spindle. The probe (shown above) comes down onto the wheel spindle to perform the test. The actual test takes fractions of a second to perform. If the part is acceptable, it passes along the conveyor to the next station. If it fails, the eddy current instrument sends a signal to the material handling PLC to send the part to a reject chute. If multiple parts are rejected in

a row, the eddy current instrument signals the operator who can check for process issues.

Figure 9 shows the material handling station in the production line. It is located just downstream of the heat treat processing station.

Figure 10 shows a set of powder metal gears that were tested just downstream of a heat treat furnace for proper hardness. The test was designed to inspect 100% of the components up to 60 parts/minute. The test was designed using eddy current encircling coils and automated sorting chutes which were designed to accommodate different sizes of rings and stars with minimal set up changes.

In order to develop a correlation between the eddy current and Rockwell hardness (HrB) test methods, two tests were conducted. 380 samples (38 sets of 10 samples) were tested with a Rockwell hardness tester and the eddy current test system. Improperly hardened specimens were included in the test batch.

The initial test results showed a very good correlation between the eddy current and Rockwell hardness tests (see Figure 3). These results indicated between 1 and 3 HrB points of variation. The eddy current test reading

Figure 8: Heat Treat Test Fixture. Figure 10: Powder Metal Gears.Figure 9: Heat Treat Testing Station in Production Line.

Figure 11: Correlation of Eddy Current and Rockwell Hardness for Powder Metal Gears.

Figure 12: Axle Flange Heat Treat Area.

54 gearsolutions.com

AbOuT ThE AuThOr:

Dan DeVries is the Director of Marketing for Criterion NDT and has been involved with non-destructive testing of manufactured components for over ten years. He has led the development and launch of eddy current test systems for heat-treat verification and flaw detection that have been adopted by major automotive OEMs and their suppliers around the world. Dan has taught at the University of Washington and holds a MS/BS in Electrical Engineering and an MBA in Marketing.

shown in blue, were more consistent than the Rockwell test results. A sample production test of 35,000 parts showed that the eddy current readings were more consistent than the sample Rockwell tests.

Figure 12 shows a flange area of a full-length axle shaft with splines on the other end. The application was to verify that

proper heat treating was applied in the area indicated. Figure 13 shows the results of a multi-frequency test with grouping of the results from different conditions. Eight test frequencies ranging from 500 Hz to 5 KHz were used for this test.

Eddy current testing can also verify that proper materials were used in fabrication. Figure 14 shows a drive gear and eddy current encircling probes. This test was put in place to verify that a supplier was delivering gears with the proper alloy.

AsseMbLy testingEddy current testing can also be used to verify proper feature manufacturing including detection of threads, broaches and splines. It can also test for proper assembly of subcomponents. An eddy current test was designed to verify that all the needle bearings used in the gear assembly shown in Figure 15 were present.

suMMAryEddy current testing offers fast, repeatable testing of gears and other critical metal components. Testing data on each component can be stored electronically and re-analyzed off-line at a later date. Eddy current test instruments are designed to integrate with PLC’s in material handling stations to set up real-time rejection capabilities. These are all features required in today’s modern manufacturing environment.

Figure 14: Drive Gear and Eddy Current Probes Used for Alloy Sorting.

Figure 15: Gear Assembly.

Figure 13: Eddy Current Testing Results for Axle Flange.

FEBRUARY 2013 55

56 gearsolutions.com

PRODUCTSHOWCASE

New products, equipment, and resources

KISSsys is KISSsoft‘s system add-on that enables the user to model complete gear units and drive trains. It is used in a variety of areas, such as the automotive industry, wind power, agricultural engineering, elec-trical tool, industrial gearbox manu-facturing, and many more. KISSsys simplifies gear calculations, calcu-lating several machine elements such as toothing, shafts, and bear-ings. Users can directly represent alternating load cases and avoid the need to carry out time-consuming and error-prone individual calcula-tions.

To calculate the different machine elements, KISSsys uses KISSsoft in the background by transferring the operating data from the kinematics calculation to the relevant KISSsoft

calculation and then displays the results in the KISSsys overview or gathers them in logs. During this process, the system can automati-cally create detailed documentation for the particular project.

Another strength of KISSsys is the integrated programming language, which enables users to define their own tasks and calculations. To do so they can either use predefined templates or write their own func-tions. For example, in-house calcula-tions can be integrated in KISSsys/KISSsoft, providing the user with a comprehensive package of calcula-tions to use.

GPKGPK is a package for sizing and rat-ing complete gearboxes, based on

KISSsys. It provides the user with 17 basic models of gearboxes as templates.

It provides a wide range of func-tions for, for example, sizing gears, shafts, and bearings. These are based on the operating data. Optimizations can be determined directly, using the price calculation functions or checks on collisions between the elements or with the housing.

GPK contains the KISSsys system add-on without the option to change the kinematics and programming. Consequently, the GPK models are restricted to the contained kinemat-ics. The user can use the gearbox variant calculation function for sizing over different stage numbers.

Gearbox Variant GeneratorThe gearbox variant generator adds an efficient method for automatically creating numerous variants of gear-boxes to KISSsys.

Usually the maximum external size is predefined, and at the same time it must be ensured that the manu-facturing costs are kept to a mini-mum. In addition, the designer must take into account weight, total power loss and other relevant factors. The designer can use the gearbox vari-ant generator to perform rapid, yet detailed investigations of the param-eters for a complete drive train so that they can compare different vari-ants of a concept.

Modern Gearbox Calculation with KISSsys

FEBRUARY 2013 57

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Stories like these are what make the TITAN experience so unique. The idea that drives the TITAN experience is providing customers a quality product quickly. It is opening doors to convenient heat treatment options that may have been closed in the past. TITAN caters to project needs by offering various sizes and configurations with long-lasting equipment and powerful technology, all within a small footprint. TITAN models can also be fitted with a number of options to increase its capabilities, making it a versatile furnace that can be used by a number of different industries for a number of different applications.

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FEBRUARY 2013 59

OMAx to Spotlight Speed and Precision of 60120 JetMachining Center at HOUSTEx

At HOUSTEX 2013, taking place Feb. 26 – 28 in Houston, Texas, OMAX Corporation will demonstrate the fast, precise cutting performance of its 60120 JetMachining Center with a 50 hp EnduroMAX® Pump, Tilt-A-Jet® cutting head and Rotary Axis in booth 1731.

Ideal for a wide range of production runs across various industry segments, such as aerospace, energy and medi-cal, the bridge-style 60120 JetMachining Center can cut complex parts from a variety of materials, including advanced composites, exotic alloys, traditional metals and rubber. Featuring a high accuracy of motion, the 60120 successfully accommodates components measuring up to 5 feet by 10 feet.

Like all OMAX JetMachining Centers, the 60120 comes equipped with the company’s intuitive Intelli-MAX® Software Suite that, when combined with the powerful, highly efficient EnduroMAX Pump, provides higher cutting speeds and greater precision than competitive abrasive waterjet machines.

The Intelli-MAX Software, which runs on the Windows® operating system, precisely calculates the velocity of a tool path at over 2,000 points per inch, allowing for complete control over the motion of an abrasive waterjet. The latest Intelli-MAX 19 software meets the growing trend of manufacturers processing 3D components by supporting up to six axes of coordinated motion. Free software upgrades are available to all OMAX JetMachining Center owners.

Offered in a variety of horsepower options, the EnduroMAX Pump increases part-processing speeds and lowers the operating costs of all OMAX JetMachining Centers. OMAX engineered the direct-drive pump for optimal efficiency, enabling it to deliver more than 85 percent of the power to the cutting nozzle.

Thanks to the Intelli-MAX Software Suite, the award-winning Tilt-A-Jet cutting head accessory offers highly advanced automated taper compensation capabilities. It achieves virtually zero taper with no reduction in cutting speed for the precision cutting of parts with square, taper-free edges, including interlocking pieces and dovetail fittings. Through the control software, the Tilt-A-Jet automatically calculates and adjusts the angle of the nozzle to accurately remove the natural taper from the finished part by transferring it to the scrap part of the material.

The Rotary Axis, capable of con-tinuous rotary motion while cut-ting, provides expanded 3D cutting capabilities via the latest Intelli-MAX 19 software. When equipped with the optional Rotary Axis, an OMAX JetMachining Center acquires six-axis cutting abilities that can create accurate, complex 3D parts from pre-existing CAD or DXF files. The Rotary Axis is ideal for cutting pipe, circular or square stock materials and incorporates multiple mounting features on the output drive shaft. The accesso-ry’s drive head also allows users to attach customized fixtures.

With so many diverse offerings in its product portfolio, OMAX Corporation offers the broadest range of table sizes, pumps, acces-

sories, software and support on the market. Moreover, the company’s abrasive waterjet technology provides a flexible and beneficial alternative to conventional machining operations. In fact, with OMAX waterjet technology, manufacturers can accomplish quick turnaround of accurate parts without the hassle of tool changes or complex fixturing, as well as achieve smooth surface finishes without the need for secondary machining.

Continued on page 64 >

820 Cochran Street • Statesville, NC 28677F: 704.872.5777 • sales@rpmachine.com • www.rpmachine.com

866.256.3708

for gear machinery…

Gould & Eberhardt is a pioneer in high-speed gear gashing with large diameter carbide-inserted cutters. Our new line of machines has a rigid design and heads engineered with state of the art gear gashing cutter technology. The exceptional results achieved in gear gashing technology have opened a wide range of applications for gear cutting in wind energy, mining, off-highway construction and other coarse pitch gearing.

“Our gasher/hobbers are equipped with the new G&E interchangeable cutter head design. This design provides the option for both internal and external heads on a single column machine with capacities up to 5.5 meters. Please visit our website for all machine offerings or call us today to request a quote.”

We are your #1 source

GE-FullPgAd_5A.indd 1 4/13/12 10:02 AM

FEBRUARY 2013 61

GEAR ACCESSORIES, PARTS & TOOLINGFELLOWS Model #10-4/10-2, All Parts Available REF#102Tilt Tables for 10-2/10-4, Qty 2 REF#102FELLOWS Parts Available For All Models REF#103BARBER-COLMAN – PARTS AVAILABLE FOR ALL MODELS REF#103 G&E – PARTS AVAILABLE FOR ALL MODELS REF#103

GEAR HOBBERS/CUTTERS CNCPFauteR #Pe-150, 6-axis cnc, 6” dia, 5 dP, 6” Face, Fanuc 18Mi REF#103G&e #60 s-2 cnc Gasher/hobber REF#103baRbeR-colMan #16-36, 16” dia, 4-axis, 6 dP, 36” Face REF#103MuiR cnc Gear hobber, 4-axis, 118” dia REF#103liebheRR #l-252 3-axis, 9.8” dia, recontrolled 2008 REF#103liebheRR #et-1802 cnc – 98” dia internal, 3-axis REF#103G&e #120Gh, cnc, Gasher/hobber, twin stanchion, 1/2 dP, 42” Face, ‘94 REF#103PFauteR P400h, 5-axis, 18” dia, 1 dP, Recontrolled ‘03 REF#103G&e #96Gh, cnc, Gasher/hobber, new ‘09 REF#103PFauteR Pe 300 aW cnc 6-axis REF#103Pfauter Pe150, 15Mb Fanuc, chip conveyor, auto load REF#107Pfauter Pe150, siemens 3M, Magnetic chip conveyor, oil chiller REF#107Pfauter Pe150, Fanuc 15, with light hob slide 8” REF#107Pfauter Pe80, 15Mb control, auto load, light curtain REF#107liebherr lc82 15M Fanuc control, auto load REF#107

GEAR HOBBERS/CUTTERSPFauteR P1251 hobbers s/n 25-276 and 25-277 REF#102PFauteR (1) Rs-00 s/n 17593 REF#102baRbeR coleMan (1) 16-36 multi cycle s/n 4404 REF#102baRbeR-colMan #16-16, Multi-cycle, dual thread Worm and/or single thread Worm REF#103G&e #48h 48” dia, 18” Face 2 dP, universal REF#103G&e #48h, 48” dia, 35” Face, 3 dP, Gooseneck attachment REF#103baRbeR-colMan #6-16, 6 Multi-cycle REF#103G&e #36h differential, excellent condition REF#103baRbeR-colMan #14-30, 14” dia, 30” Face, 3.5dP REF#103baRbeR-colMan #14-15, 14” dia, 15” Face, 1 to 4 start Worm, several REF#103baRbeR-colMan #16-16, 16” dia, 16” Face, 6dP REF#103baRbeR-colMan #16-36, 24” dia, c-Frame style, 4 1/8” bore REF#103

baRbeR-colMan #16-56, 16” dia, 56” Face, differential REF#103G&e #24h universal head, infeed, tailstock, differential, ‘50’s REF#103liebheRR #l-650, 26" dia cap, 14.5" Face, 2.5 dP, new ‘70’s REF#103G&e #16h Gear hobber, 16"dia REF#103baRbeR-colMan #6-10, 6” dia, 10” Face, 16 dP REF#103KoePFeR #140 , 2.75” dia, 4” Face REF#103 lansinG #Gh-50, 50” dia, 17.75” Face, 2 dP REF#103liebheRR #l-252, 9.8” dia, 7.9” Face, 4.2 dP REF#103baRbeR-colMan tyPe t REF#103G&e #36hs 36”dia, 14” Face 3 dP REF#103PFauteR #P-3000, 120” dia, single index REF#103schiess RFW-10-s 55” dia REF#103schiess 1 RF-10, dia 60” 150” l, .50 dP REF#103G&e #40tWG, 48” dia, 18” Face, 3 dP REF#103G&e #60s, 72” dia, 14” Face, 1.25 dP REF#103G&e #72h, 72” dia, 24” Face, 1 dP REF#103 G&e #96h, 104” dia, .50 Face, 1.25 dP REF#103PFauteR #P-630, 25” dia REF#103 PFauteR P250 10” dia REF#103Ge/Fitchburg hobber 32” dia, 72” Face 1.25dP REF#103JF Reinecker 40” dia 35” Face REF#103liebheRR l-160-R 6.5” dia REF#103MiKRon #102.04 , 4’ dia, 5” Face REF#103PFauteR P-900 36” dia REF#103baRbeR-colMan #25-15 25” dia, 15” Face, 2.5 dP REF#103PFauteR #P-630R, 25" Max. spur dia, 12" Max Rotor dia. 12" REF#103baRbeR-colMan 2 1/2 -4, s/n 119, ’62 hi-Production spur Gear REF#104baRbeR-colMan 6-10 syKes, triple thrd w/lever operated collet assy REF#104baRbeR-colMan 6-10 b&c ltd, s/n 8079, triple thrd REF#104baRbeR-colMan 6-10, s/n 4626, ’57 triple thrd 3” hob slide REF#104baRbeR-colMan 6-10, s/n 4659R, ’56 triple thrd adj ctr assy REF#104baRbeR-colMan 6-10, s/n 4665, ’57 Fine Pitch Prec triple thrd REF#104baRbeR-colMan 6-10, s/n 4701, ’58 triple thrd w/Power down Feed REF#104baRbeR-colMan 6-10 M/c, s/n 4755, ’59 triple thrd w/Mc conversion REF#104baRbeR-colMan 6-10 Multicycle, s/n 4778R87, ’60 (’87 Rebuild), sgl thrd hi-spd REF#104baRbeR-colMan 6-10 M/c, s/n 4913, ’63 triple thrd w/90 deg hob slide REF#104baRbeR-colMan 6-10 Multicycle, s/n 5055, ’66 triple thrd, 800 RPM REF#104baRbeR-colMan 6-10, s/n 5141, ’67 triple thrd w/Prec hob shift REF#104baRbeR-colMan 6-10 Multicycle, s/n 5148, ’68 triple thrd, 800 RPM REF#104baRbeR-colMan 6-10 Multicycle, s/n 5259, ’75 triple thrd w/auto hob shift REF#104baRbeR-colMan 6-10, s/n 5353, ’77 triple thrd w/3” hob slide, 800 RPM REF#104baRbeR-colMan 6-10, s/n 5394, ’81 Fine Pitch triple thrd w/dwell & hob Rev REF#104baRbeR-colMan 6-16 M/c, s/n 5238, ’70 triple thrd, Recon ‘02 REF#104baRbeR-colMan 6-10, s/n 5407, ’82 auto w/Plc control REF#104baRbeR-colMan dhM, s/n 105, ’42 double thrd REF#104baRbeR-colMan 14-15, s/n 635R, ’53 dbl thrd, Fact Reb REF#104baRbeR-colMan 14-15, s/n 745, ’55 dbl thrd w/dwell REF#104baRbeR-colMan 14-15 dual Fd, s/n 938, ’62 dbl thrd, comp Reco REF#104baRbeR-colMan 14-15, s/n 1055, ’65 dbl thrd w/new hyd sys REF#104baRbeR-colMan 14-15, s/n 1131, ’66 dbl thrd w/hyd tailctr REF#104baRbeR-colMan 14-15 dual Fd, s/n 1261, ’67 dbl thrd w/hyd live ctr REF#104baRbeR-colMan 14-15 dbl cut, s/n 1278, ’68 dbl thrd w/4-1/8” bore REF#104baRbeR-colMan 14-30 dual Fd, s/n 1371, ’71 4-thrd w/sizing cycle REF#104baRbeR-colMan 22-15, s/n 923, ’62 dbl thrd, dbl cut REF#104baRbeR-colMan 16-11, s/n 184, ’50 dbl thrd w/Vert dRo REF#104baRbeR-colMan ahM, s/n 1896, ’42 sgl thrd w/3 Jaw chuck REF#104baRbeR-colMan 16-16, s/n 2745, ’51 sgl thrd w/90 deg hd REF#104baRbeR-colMan 16-16, s/n 3171, ’53 dbl thrd, spanish nameplates REF#104baRbeR-colMan 16-16, s/n 3580, ’59 dbl thrd w/diff & auto hobshift REF#104baRbeR-colMan 16-16 Multicycle, s/n 3641, ’60 dbl thrd w/diff REF#104baRbeR-colMan 16-16, s/n 3660, ’57 sgl thrd REF#104baRbeR-colMan 16-16, s/n 4136, dbl thrd, “c” style end brace w/diff REF#104baRbeR-colMan 16-16 Multicycle, s/n 4170, dbl thrd w/Jump cut cycle “c” style REF#104baRbeR-colMan 16-16, s/n 4473, ’73 4-thrd w/Workclamp cyl “c” style REF#104baRbeR-colMan 16-16 Multicycle, s/n 4520, ’75 dbl thrd w/Gooseneck slide REF#104baRbeR-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#104baRbeR-colMan 16-36, s/n 4090, ’66 dbl thrd, “c” style end brace REF#104baRbeR-colMan 16-36 Multicycle, s/n 4232, ’68 dbl thrd “c” style end brace w/diff REF#104baRbeR-colMan 16-56, s/n 3136R84, ’53 (Reb ’84), dbl thrd REF#104baRbeR-colMan 10-20, s/n 6700045890, ’76 dbl thrd w/2 cut cycle REF#104tos oFa series conventional Gear hobbers, 12” & 40” dia REF#105tos oha series conventional Gear shapers, 12” & 40” dia REF#105tos Fo-16 with single index 72” cap. REF#106

GEAR PINION HOBBERS & SPLINE MILLERShuRth #KF-32a 15” dia, 59” Face, ‘67 REF#103Ge/Fitchuburg Pinion hob 32” dia, 72” Face REF#103MichiGan tool #3237 REF#103FitchbuRG Pinion hobber 42” dia, 72” dia REF#103craven horizontal 36” dia 96” length 73/4” hole REF#106

GEAR HOB & CUTTER SHARPENERS (incl CNC)baRbeR-colMan #6-5, 6" dia, 5" length, Manual dresser, ‘57 REF#103FelloWs #6sb, helical cutter sharpener, 6” dia, up to 50 degrees REF#103KaPP #as-305Gt, 1 dP, 28" Grind length, 10" diam., str. & spiral REF#103KaPP #as204Gt, 10” dia, Wet Grinding, cbn Wheels, ‘82 REF#103RedRinG Model #sGh "PReiFoRM" shaVe cutteR GRindeR/shaRPeneR REF#103staR 6X8 hob shaRPeneR PRecision GeaR & sPline hobbeR REF#103baRbeR-colMan 2-2 1/2 , 2.5” dia REF#103KaPP #ast-305b, 27.5” dia, REF#103KaPP as-410b REF#103Gleason #12 sharpener, 3-18” cone REF#103Red Ring shaving cutter sharpener Periform REF#103star #6 Gear cutter sharpener REF#103star 4hs hob sharpener REF#103star hhs horizontal hob sharpener cnc, Max dia 10” Max length 12” new 1990 REF#103baRbeR-colMan 2 1/2-2, s/n 16, ’66 Wet w/auto Feed REF#104baRbeR-colMan 6-5, s/n 110R, ’55 Wet w/auto dress & sparkout REF#104baRbeR-colMan 6-5, s/n 396, ’66 Wet w/auto dress & sparkout REF#104baRbeR-colMan 6-5, s/n 433, ’69 Wet w/auto dress & sparkout REF#104baRbeR-colMan 10-12, s/n 643R83, Wet w/auto dress, Pc control, Fact Reb ‘83 REF#104tos oha series cnc Gear shapers, 12” & 40” diameter REF#105 tos oFa series cnc Gear hobbers, 12” & 40” diameter REF#105

GEAR SHAPERS CNC36” shapers, 14” throat Risers, 53” of swing, Qty 3 REF#102FelloWs #10-4/10-2, Qty 150 REF#102hydRostRoKe #50-8, Qty 2 REF#102hydRostRoKe #20-8, Qty 5 REF#102hydRostRoKe #Fs630-125, Qty 1 REF#102hydRostRoKe #Fs400-90, Qty 2 REF#102FelloWs #20-4, Qty 6 REF#102FelloWs #48-8Z, Qty 1 REF#102FelloWs #Fs-180, 3-5 axis, 7” dia, 1.25” Face., 6 dP, new ‘88 REF#103liebheRR #Ws-1, 4-axis cnc, 8" od, 2" stroke, Fanuc 18Mi REF#103LoRenZ # ls-180, 4-axis cnc, 11” od, 2” stroke, 5 dP REF#103loRenZ #ls-304 cnc Gear shaper 5-axis heckler & Koch control REF#103FelloWs Fs400-125, 16” dia, 3.5 dP 5” Face REF#103FelloWs #10-4 3-axis (a/b), 10" dia, 4" Face, 4 dP new .’09 REF#103 FelloWs #10-4 2-axis, 10” dia 4” Face REF#103FelloWs #20-4 3-axis 10” dia, 4” Face REF#103FelloWs Fs400-90 hydro-stroke Gear shaper cnc nominal Pitch 15.7" REF#103Fellows 20-8, cnc Gear shaper, Remanufactured and recontrolled REF#103Fellows Model Z gear shaper REF#103lorenz sn4 Gear shaper, Max od 7”, 2” Face, Max 6 dP with loader REF#103RP/ stanko 48-8 Remanufactured Gear shaper, Fanuc 3 axis, 18i M control, new 2010 REF#103

GEAR HOBBERSbarber colman Model 4-4hRs, hob sharpener 4” Max od, 4” length REF#103Fellows Fh 200 Gear hobber, universal hobbing Machine REF#103barber colman 6-10, cnc, cRt 5 axis, 6” dia, 10.5” travel, 6 dP REF#103

FEATUREDsUppliersMidwest Gear Corporation — REF #101Phone: 330-425-4419 • Fax: 330-425-8600Email: sales@mwgear.comWebsite: www.mwgear.com

New England Gear — REF #102Phone: 860-223-7778 • Fax #:860-223-7776Email: jeff@newenglandgear.comWebsite: www.newenglandgear.com

R. P. Machine Enterprises, Inc. — REF #103Phone: 704-872-8888 • Fax #:704-872-5777Email: sales@rpmachine.comWebsite: www.rpmachine.com

Repair Parts, Inc. — REF #104Phone: 815-968-4499 • Fax #:815-968-4694Email: rpi@repair-parts-inc.com Website: www.repair-parts-inc.com

Havlik International Machinery, Inc. — REF #105Phone: 519-624-2100 • Fax: 519-624-6994Email: havlik@bellnet.caWebsite: www.havlikinternational.com

GQ Machinery Inc. — REF #106Phone: 516-867-4040 • Fax: 516.223.1195Email: george@gqmachinery.comWebsite: www.gqmachinery.com

Gibbs Machinery Company — REF #107Phone: 586-755-5353 Fax: 586-755-0304Email: rj@gibbsmachinery.comWebsite: www.gibbsmachinery.com

MACHINERYContact Gear Solutions at

800-366-2185 to list your machinery.

62 gearsolutions.com

barber colman hobber type t REF#103barber colman model #14-15 Gear hobber, horizontal heavy duty REF#103barber colman Model #16-36 Gearhobber REF#103barber colman Model #16-56, 16” dia, 56” Face, adj. air tailstock REF#103barber colman Model 2.5-2 gear hobber, 2” length Manual dresser REF#103G&e Model 5.2 cnc internal Gear gashing head REF#103Jeil Jdh-3, Gear hobber, Max dia 31.5”, 3dP, 22.8 table diameter REF#103Jeil JdP-2, Gear hobber, Max dia 26”, 4 dP, 19.5” table dia, differential and tailstock REF#103liebherr et 1802, internal Gashing head, Fanuc 16i control, 98”Max dist 17” Face REF#103liebherr l-402 Gear hobbing Machine, new 1977 REF#103liebherr lc 752, 6 axis cnc hobber, Max od 29.5”, Max Face width 23.6” REF#103Micron Model 120.01 w/bevel cutting attachment, new 1975, 1.6” dia, 25.4 dP REF#103nihon Kakai Model ntM-3000, spline hobbing Machine, Max dia 400mm, 3150mm between center REF#103Pfauter P900 Reman and Recontrolled, Max od 120” REF#103Pfauter Model Pe125 cnc Gear hobber REF#103Pfauter model Pe300 cnc, Max od 12”, Max gear face 15”, 3 dP, 6 axis REF#103Reinecker heavy duty Gear hobber REF#103scheiss Model RF10 horizontal hobber, 60” dia, 144” face, 180”cc, 8 dP REF#103G&e 96h, roughing & finishing 104” dia. REF#106tos Fo-16 single index 80” dia. yr 1980 REF#106craven spline & pinion hobber 36” x 96” REF#106G & e 48h 48” dia. diff, ob, change gears REF#106Pfauter hobber P-1800 70” dia. 29” face yr 1980 REF#106lees bradner 7Vh, 8”Pd, 10” Face, , Magnetic chip conveyor , hob shift REF#107lees bradner 7Vh, 8”Pd, 4Pd, Magnetic chip conveyor, hob shift REF#107Mitsubishi Model Gh300, 15.7”, 3 dP, differential, 2 cut REF#107tos 32a, 320mm Gear dia.,3.6 dP, differential, 2 cut REF#107Gleason 775 8”Pd, high helix head, infeed, Very light use REF#107barber c. 16-15, 7 ½” hob, crowning, differential, 2 cut REF#107barber colman 14-15, 2 cut, Fast approach, 4” bore REF#107barber colman 16-36, type a – Very Good, double thread index REF#107G & e Model 48hs 48”Pd, 18” Face, 2.5 dP REF#107

GEAR SHAPERSFelloWs #10-2, (10” dia), 2” Face REF#102FelloWs #10-4, (10” dia), 4” Face REF#102FelloWs (200) 10-4 / 10-2 shapers REF#102FelloWs (1) 50-8 hydrostroke shaper s/n 36607 w/ 6 axis 16iMb Fanuc (2009) REF#102FelloWs (1) 20-8 hydrostroke shaper s/n 35932 w/ 6 axis 16iMb Fanuc (2009 REF#102 FelloWs (1) #7 125a Face Gear Machine REF#102FelloWs (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#102FelloWs (1) Fs630-200 hydrostroke shaper s/n 36943 w/ 6 axis 16iMb Fanuc (2009) REF#102FelloWs (3) tilt table 10-4 / 10-2 w/ 4 axis 21i Fanuc controller (2009) REF#102FelloWs (2) swing-away center support for 10-2 / 10-4 REF#102FelloWs (1) Fs630-170 hydrostroke shaper s/n 36732 w/ 6 axis 16iMb Fanuc (2009) REF#102FelloWs (2) Fs400-170 hydrostroke shaper w/ 6 axis 16iMb Fanuc (2009) REF#102FelloWs (4) Fs400-125 hydrostroke shaper w/ 6 axis 16iMb Fanuc (2009) REF#102FelloWs (1) 20-4 shaper s/n 35687 w/ 4 axis 21i Fanuc controller (2009) REF#102FelloWs (1) 48-8Z shaper w/ 14” throated riser (53” of swing) REF#102FelloWs (1) horizontal Z shaper s/n 21261 REF#102FelloWs (1) 4-b steering sector Gear shaper w/ 18iMb 4 axis Fanuc controller s/n 34326 REF#102FelloWs (1) 36-10 Gear shaper REF#102FelloWs (1) 10x6 horizontal Z shaper REF#102FelloWs (1) 36-6 Gear shaper w/ 13” riser s/n 27364 REF#102FelloWs (1) 10-4 shaper w/ 3” riser w/ 4 axis 21i Fanuc controller (2009) REF#102all Parts for 10-4/10-2 Fellows Gear shapers REF#102FelloWs #36-8, 36” dia, 8” Face REF#103FelloWs #100-8 100” dia, 8” Face REF#103FelloWs #612a, 615a, #645a REF#103FelloWs #10-4, 10” dia, 4” Face, 4 dP REF#103FelloWs #4a Versa, 10” dia, 3” Face, 4 dP, new ‘70’s REF#103FelloWs #10-2, 10” dia, 4” Face, 4 dP REF#103FelloWs #20-4, 20” dia, 4” Face, 4 dP, ‘70’s REF#103FelloWs #3-1,/3Gs, 3” Max dia, 1” Face, Pinion supp, high Precision REF#103FelloWs #48-6 inteRnal GeaR shaPeR only,0-72"od,6" Face REF#103MaaG #sh-150, 57" dia.12.6" Face REF#103PFauteR #sh-180 shobber 7" capacity hobbing, 9.45" cap REF#103FelloWs #36-6 Max dia 36” 6” Face, 3 dP REF#103

FelloWs #hoRZ Z shaPeR, 10 x 6 dia 27.6 Face 8.5” REF#103FelloWs #4Gs & 4aGs, 6” dia, 2” Face, 4dP, ’68, Ref.# several REF#103FelloWs #624a, 18” Max dia, 5” Face REF#103FelloWs #7, #7a, #715,# 75a, #715, #725a, 7” dia, 0-12” Risers,

several avail REF#103MichiGan #18106 sheaR-sPeed GeaR shaPeR,14" dia, 6"Face REF#103FelloWs Model Z shaper, 5" stroke, ‘50’s REF#103staehely shs-605, Gear shaper REF#103FelloWs #6, #6a, #61s, From 18”-35” dia, 0-12” Risers REF#103FelloWs #8aGs Vertical Gear shaper, 8” dia, 2” Face, 6-7 dP REF#103tos oha50 cnc 5 20” dia 5” Face REF#105Fellows 36-6 shaper (2) 12.5" Risers 6" stroke Mint yR 1969 id 3616 REF#106Fellows 36-6, shaper W/6” riser, change gears REF#106Magg shaper sh4580-500s, 206”dia. 26” face REF#106Magg shaper sh250, 98” dia. 26” face REF#106Fellows #10-4,7” riser yr 1980 REF#106Fellows 3”, 6”, 7”, 10”, 18”, 42”, 100, some cnc REF#107

GEAR DEBURRING/CHAMFERING/POINTING

cRoss #50 Gear tooth chamferer, 18” dia, single spindle REF#103Redin #20d, 20” dia, twin spindle, deburrer/chamfer REF#103saMPutensili #sct-3, chamf/deburrer, 14” dia, 5” Face, ‘82 REF#103saMPutensili #sM2ta Gear chamfering Mach, 10” Max dia, (3) new ‘96 REF#103Redin #24 cnc dia 4” setup Gear deburring REF#103

cRoss #60 Gear tooth chamferer, 10” dia, single spindle REF#103FelloWs #100-180/60 cnc Max dia 180”, single spindle REF#103ciMtec #50 Finisher REF#103cRoss #54 Gear deburrer, 30” dia, 18” Face REF#103Red RinG #24 twin spindle dia 4” REF#103Gleason GtR-250 VG cnc 5-axis REF#103Gleason- hurth Model Zea 4, Max dia 250mm, Max Module 5mm REF#103Redin Model 36 universal chamfering and deburring Machine, Max od 36”, twin spindle,

tilt table REF#103samputensili sct3 13.7”, sM2ta 10”, (5), 2003 REF#107Mitsubishi Ma30 cnc, 11”Pd, Fanuc, Powermate, 1999 (2) REF#107

GEAR HONERS

Kapp #cX120 coroning 4.7” dia REF#103Red Ring Ghd-12, 12” dia, 5.5 stroke REF#103Red Ring GhG, 12” dia, 5.5 stroke REF#103Kapp #Vac65 coroning 10” dia REF#103

GEAR SHAVERS

Red Ring #GcX-24" shaver, 24” dia, 33” stroke REF#103Red Ring #Gcu-12, 12” dia, 5” stroke REF#103

Red Ring #Gcy-12, 12” dia, 5” stroke REF#103Red Ring Gci 24, 12.75” dia, 5” stroke REF#103Kanzaki model GsP 320 Gear shaver REF#103Red Ring Gcu 12 crowning, 1956 to 1988 (6) REF#107Mitsubishi Fb30, 12.2 cnc Fanuc, 1997 REF#107sicmat Raso 100, cnc Fanuc 16M, new, Guarantee REF#107

GEAR GENERATORS

Gleason #37 str. bevel Planer, 6” dia REF#103Gleason #496 straight.& spiral. 7.5” dia REF#103Gleason 725-Revacycle, 6” dia REF#103Gleason 726-Revacycle, 5” dia REF#103Farrel sykes Model 12c herringbone max dia 264”, max face width 60” REF#103Farrel Model 5b herringbone gear generator. REF#103Gleason 529 gear quench press, auto cycle 16” diam, new 1980 REF#103Gleason 614 hypoid finishing machine, 10.5” pitch, dia 5.25” Max cone dist REF#103oerlikon/klingelnburg Model c28, Max dia 320 mm, Max Module 7.5 mm REF#103Gleason Model 26 Quench press and hypoid Generator Max od 16”, Max face Width air cylinder

REF#103Gleason Model 36 Gear Quenching Press, Max Ring 28” od, 8” Face, universal REF#103 Gleason Model 450 hc cnc hypoid cutter, Face width 2.6”, fanuc 150 controls REF#103Gleason 24 Rougher, Gears, Finishing tool holder REF#10712” Gleason, Gears, Gauges tool blocks REF#107Gleason 116 Rougher & Finisher (6) REF#107Gleason Phoenix 175hc cnc – 1994 REF#107Gleason 22 Rougher & Finisher (8) REF#107Gleason 610 combination Rougher & Finisher, 1988 REF#107Gleason 608 & 609 Rougher & Finisher REF#107

Gleason 7a, 7”Pd helical Motion, Gears & cams REF#107Gleason cutters, 3” to 25” in stock, 1000 REF#107

GEAR GRINDERS#27, #137, and #463 Gleason hypoid spiral bevel gear grinder generating cams (2 full sets) REF#102springfield Vertical Grinder, 62" table, #62aR/2cs, 3.5a Rail type, 70" swing REF#102ReishaueR Za, Gear Grinder, 13" dia, 6" Face, strait & helix REF#103Gleason #463, 15” dia REF#103hofler model Rapid 2000l, cnc Grinder, Max od 78”, cnc dressing REF#103Matrix model 78, Reman cnc thread grinder, 24” dia, 86” grind length, 106 between centers REF#103Mitsu seiki Model GsW-1000 Gear Grinder REF#103Reishauer RZ 362 as, cnc Grinder, Max dia 360mm REF#103sundstrand/arter Model d12 Grinder REF#103teledyne-landis Gear Roll Finishing Machine, 5” diam, 42k lbs Rolling Force REF#103Reishauer RZ301as cnc, 13” Measuring system (3) REF#107Reishauer Zb, 27.5” Pd Gears, coolant REF#107

GEAR RACK MILLERS/SHAPERSMiKRon #134 Rack shaper, 17.4" length, 1.1" Width, 16.9 dP REF#103syKes VR-72 Vert Rack shaper, 72" cut length, 4dP, 4" stroke, ‘80 REF#103Fellows 4 – 60 Rapid traverse, 2 cut REF#107

GEAR THREAD & WORM, MILLERS/GRINDERSbaRbeR-colMan #10-40, 10" dia., 40" length, 4 dP REF#103eXcello #31l, external thread Grinder, 5" od, 20" Grind length REF#103eXcello #33 thread Grinder 6” dia 18” length REF#103huRth #KF-33a Multi-Purpose auto-Milling Machine 88” REF#103lees bRadneR #ht12x102, extra large capacity REF#103lees bRadneR #ht 12"x 144" thread Mill, 12" dia, REF#103 lees bRadneR # lt 8” x 24” 8” dia REF#103 holRoyd 5a 24.8 “ dia REF#103 lees bRadbeR WoRM MilleR REF#103 dranke cnc internal ball nut Grinder REF#107

GEAR TESTERS/CHECKERS (incl CNC)FelloWs (1) Rl-600 Roll tester s/n 35814 REF#102FelloWs (1) 24h lead checker s/n 32289 REF#102Gleason (1) #14 tester s/n 31907 REF#102Gleason (1) #6 tester s/n 19316 REF#102FelloWs (1) 20 M Roller checker REF#102FelloWs (1) 20 M w/ 30” swing Roller checker REF#102FelloWs (1) #8 Micaodex s/n 36279 REF#102david brown #24 Worm tester REF#103Gleason #4, #6, #13 and #17 testers REF#103hofler eMZ-2602 int/ext Gear tester 102” REF#103Klingelnberg #PFsu-1600 Gear tester-2001 REF#103Kapp hob checker WM 410 REF#103Maag #es-430 Gear tester REF#103Maag #sP-130 lead and involute tester REF#103national broach Gear tester GsJ-12 REF#103oerlikon #st2-004 soft tester REF#103Maag #sP-60- electronic tester REF#103Parkson #42n Worm Gear tester REF#103Vinco dividing head optical inspection REF#103Gleason model 511 hypoid tester Max dia 20”, max spindle centerline 3.5” REF#103Klingelnberg Model PFsu-1600 63” dia, 1.02 dP, Rebuilt REF#103MaaG es401 Pitch tester With Process computer REF#103Fellows 12 & 24M involute, 12 & 24 lead REF#107Fellows 36” space tester, hot Pen Guaranteed REF#107Gleason 17a Running or Rebuilt Guaranteed REF#107Gleason 511, 20” Reconditioned in 2010 Guaranteed REF#107Gleason 27, 26”, Guaranteed REF#107Gleason 515, 24” REF#107Gleason 523, 20” Reconditioned, 2010 REF#107

MISCELLANEOUSWaRneR & sWaysey #4a M-3580 turret lathe, 28 1/4 swing, 80” centers, 12” spindle hole 50/25 Motors, 480/3 Phase, year 1965 REF#101springfield Vertical Grinder, 62" table, #62aR/2cs, 3.5a Rail type, 70" swing REF#102Gleason #529 Quench, 16" diameter REF#103Klingelnberg Model lRK-631 Gear lapper REF#103VeRtical tuRninG lathes and MoRe - Please check our Website to View our entire inventory REF#103tos su & sus series conv lathes REF#105tos sua series cnc Flat-bed lathes REF#105change gears for G & e hobber REF#106

Seeking OppOrtunity?

Scan the new Gear Solutions Website to enjoy a host of features, including:

• Our new jobs listing, for employers and job seekers alike

• Events calendar to keep you informed

• A searchable articles archive, downloadable individually

• View the digital magazine, or download entire issues

• Vendor listings, along with our annual Buyer’s Guide

• Company profiles and Q&As

• Connect to the gear industry through social media

• Gear industry news from around the world

Visit www.gearsolutions.com today, and get connected!

64 gearsolutions.com

OML’s new Genius 5-axis vise turns work-holding concepts on their head with a unique design that maximizes clamp force at the top of the jaws by pulling them closed at the top with a collapsing lead screw, while holding the bottom of the jaws in place with an opposing force screw. Available from Lexair, Inc., the dual-screw, pull-to-close Genius vise completely eliminates the ten-dency of traditional vise jaws to splay apart at the top, which requires machine opera-tors to hammer a workpiece down against the stops as the jaws close and clamp force increases. By holding the vise jaws apart at the bottom and pulling closed at the top, the Genius vise actually pulls the workpiece down against the stops as closing force increases. The Genius vise is available in two sizes, capable of holding parts up to 8 inches, with maximum clamp force of 9,000 pounds.

The Genius vise is specifically designed for precision 5-axis milling with trunion-table machines. The adaptable vise easily secures oddly-shaped workpieces, such as turbine blades and blisks, and presents them to the spindle with minimal obstruc-tion, reducing setups and ensuring repeat-ability of 0.0008”.

Intended for production machining, the vise is built with precision, hardened, and ground steel components. The jaws are guided on two heavy steel shafts, allow-ing quick, accurate centering on a pallet or machine table. A telescoping stainless steel cover fully encloses the collapsing lead screw to protect it from chips and coolant.

The Genius vise comes standard with one pair of positioning keys, grippers and wrench. A wide variety of stops, jaw plates, gripper inserts, and other accessories are available. Custom opening sizes and other variations are available on request. For details, see omlusa.com or call 859-255-5001.

Genius Vise is Smartest New Workholding device For Precision 5-Axis Milling

Continued from page 59 >

Continued on page 66 >

FEBRUARY 2013 65

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· Precision Quality up to AGMA 12· Prototype & Production quantities· Breakdown Service Available· Reverse Engineering · Unique Tooth Configurations· Heat Treating· Complete CNC Machining

66 gearsolutions.com

CIMCOOL’s Elite Series of Products is Top of the Line

CIMCOOL® Fluid Technology, the leader in fluid tech-nology worldwide, offers some of the most techno-logically advanced fluids for use in industrial opera-tions. The 600 series, or the Elite Series of fluids, is CIMCOOL’s top of the line product.

CIMTECH® 609-E and CIMTECH® 609G are “hybrid synthetics,” utilizing a combination of patented and commercial lubricants for superior grinding and excel-lent machining performance. They are also functional for stamping and drawing applications. CIMTECH 609-E is a second-generation product that has much improved bacteria and mold protection without any loss of lubricity. It offers up to double the life of other similar products in well-maintained systems. CIMTECH® 610 is an innovative new generation syn-thetic metalworking fluid featuring a hybrid blend of patented and synthetic lubricants for use in heavy to severe duty applications. This unique blend of lubri-cants provides synergistic performance on difficult-to-machine-ferrous and non-ferrous alloys. CIMTECH® 612NF is a hybrid synthetic utilizing patented and commercial lubricants in combination for superior grinding and excellent machining performance. With

an excellent grinding ratio, tool life, finish, and sump life, this product can be used on both ferrous and most non-ferrous applications.

QUANTALUBE® 270XL is a new water soluble, “super-lubricant” metalworking fluid designed for heavy-duty grinding and machining operations. QUANTALUBE 270XL’s patented Extreme Pressure lubricant package provides outstanding stock removal, permitting high productivity increases. This product is recommend for all ferrous metals except gray cast iron. It can be used for individual machines or central systems. QUANTALUBE 270XL has dramatically improved many traditional “heavy-duty” operations to provide large increases in process throughputs and tool life.

All CIMCOOL products are backed by the company’s “no-hassle” performance guarantee and free trial assurance. For additional information, please visit our website at www.CIMCOOL.com, and click on the MSDS and Product Information menu. CIMCOOL Fluid Technology is a global manufacturer of metalwork-ing fluids. The company is certified ISO 14001, ISO 9001. Pink Trade Dress is a registered trademark of Milacron LLC.

Continued from page 64 >

FEBRUARY 2013 67

advertiserINDEX

COMPANY NAME .............. PAGE NO.ALD Thermal Treatment ............................................................. 64

All Metals & Forge Group ........................................................... 55

Allen Adams Shaper Services .................................................... 65

Apollo Broach Inc ...................................................................... 65

Bourn & Koch ............................................................................ 67

Circle Gear & Machine Co Inc .................................................... 57

CNC Machinery Sales Inc .......................................................... 58

Comtorgage Corporation ............................................................. 9

DT Technologies ........................................................................ 47

Encoder Products Company ...................................................... 53

Engineered Tools Corp ..........................................................34-35

Forest City Gear ......................................................................... 48

Gear Motions Inc ....................................................................... 65

Gear Solutions Online ................................................................ 63

GearTec Inc ............................................................................... 40

Gleason Corporation .................................................................. 23

GMTA (German Machine Tools of America) .............................. IBC

Hanik Corporation ...................................................................... 67

Hilco .......................................................................................... 41

Ingersoll Cutting Tools ................................................. 11,13,15,17

Innovative Rack & Gear .............................................................. 65

Ipsen International...................................................................... 27

KAPP Technologies ................................................................... IFC

KISSsoft USA LLC ..................................................................... 44

Koro Sharpening Service ........................................................... 65

Liebherr Gear Technology Inc ....................................................... 2

Luren Precision .......................................................................... 65

McInnis Rolled Rings ................................................................. 10

MicroGear .................................................................................. 53

Mitsubishi Heavy Industries America Inc .................................... BC

New England Gear ....................................................................... 7

Overton Chicago Gear ............................................................... 31

Perfection Industrial Sales/Hilco Industrial Europe LLC ............... 18

Process Equipment Company .................................................... 12

Proto Manufacturing Ltd ............................................................ 14

Quality Transmission Components ............................................. 57

R P Machine Enterprises Inc ................................................. 45,60

Raycar Gear & Machine Co ........................................................ 48

Repair Parts Inc ......................................................................... 47

Russell Holbrook & Henderson ................................................... 36

Schafer Gear Works Inc ............................................................. 16

STD Precision Gear ................................................................... 44

Stock Drive Products/Sterling Instrument ................................... 52

Stor-Loc .................................................................................... 58

The Broach Masters Inc ............................................................... 4

The Company Corporation ......................................................... 65

TMFM LLC ................................................................................ 52

Toolink Engineering Inc ................................................................ 1

68 gearsolutions.com

Innovative Rack and Gear services the oil, aerospace, steel, marine, automa-tion, machine tool, computer, medical, and precision instrument industries and supplies gear racks to many well-known catalog companies. President Zen Cichon gives Gear Solutions the inside track on how the word “expan-sion” can mean many things.

GS: I understand you’ve grown and acquired some new, rather unique machines in the last few years.ZC: In 2009 we purchased a hard-rack mill that allows us to cut up to 60 Rc hardness using special cutters. The other machines we possess are for soft-rack cutting of about 30 Rc with 40 Rc max using high speed cutters. The HR2000 from Saikuni gave us the capability to cut hard-racks as opposed to grinding, which is a unique feature. Normally hardened racks require grinding the teeth to take out the distortion after hardening. We pur-chased this machine because it’s a more flexible machine. It can be used for either purpose, hard or soft. It helps us get into the higher-precision hardened rack market because it is very comparable to ground rack in tolerances and finish. We also acquired in previous years another soft-rack mill to increase our capacity and a larger machining center to allow us to do secondary operations on larger racks.

prEsidENTiNNOvATivE rACk ANd GEAr

GS: You’ve got the new machines. What about new employees, sales, capabilities?ZC: Since 2004, we’ve grown to about 20 employees. We’ve doubled our sales. We’re more diverse in terms of the parts that we do: precision parts, larger racks, etc. When we acquired new machines in 2009, we had to rent out additional space that was about 3,300 square feet. Then, in the winter of 2011, we moved into our current location of 20,000 square feet. This allows for future expansion. Having two locations made it dif-ficult to run a lean operation.

GS: You’re expanding in more ways than one, though. Not just outwardly…ZC: Right. At this point, rather than focusing on expansion, we’re focusing on efficiency in what we do, squeezing as much as we can out of what we have. Right now we’re installing a new ERP (Enterprise Resource Planning) system, allowing us to control many aspects of manufacturing. This will keep track of job performance, efficiency, and scheduling. It will give us a better picture of how each part is going through our shop.

We’re also working on getting our website updated to appear more professional, with applications such as PayPal for customers to pay online, request for quotes, and being able to attach prints that customers have, along with employment inquiries.

GS: It sounds like you’re poised to do some serious growth in the next few years.ZC: Right now, we have the tools to do that. We just have to act on it and bring it to completion. We’re not the small company that we were before. We have a much larger presence out there, dealing with larger companies and promoting a more professional image. In the smaller building, for example, we didn’t have a conference room — every-body was packed into two rooms. Now we’ve got individual offices and a conference room. We’ve had customers see the change in us, and they like it. We’ve risen to a different level. We’ve got serious tools to produce our gear racks, and we want people to know that. Now that we’re more diverse, we can help people with large racks, small racks, pre-cision racks, or commercial racks in many shapes and materials. We can produce racks for the oil industry, naval systems, medical companies, OEMs, and the machine tool and automation industries just to name a few. We’re constantly working on improvements in all areas of manufacturing.

GS:What kind of marketing strategies does a company like Innovative Rack and Gear employ to self-promote?ZC: We’ve been fortunate to have a great reputation as our driving sales force in the gear rack industry. Word of mouth has helped us grow tremendously in the past eight years. The Thomas Register was our primary sales tool in the beginning, but networking with other companies and getting our name out at the Gear Expo really helped, as well as advertising in Gear Solutions. We are also always open to having outside sales people work with us.

zenCiChon

Q&A

TO lEArN mOrE:For more information call (630) 766-2652 or visit www.gearracks.com.

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The Game-Changing Mitsubishi GE Series CNC Gear Hobbing Machines.A quick glance at Mitsubishi’s GE Series Gear hobbing machine doesn’t reveal the truth behind it’s real power. However, when you evaluate the output the full picture is dramatic and clear. With an all new, utlra-effi cient dry cutting design, the GE series machines produce gears up to 50% faster than previous technologies—with all the precision your specifi cations demand. This kind of boost in productivity is sure to help you be more competitive in the marketplace and pump up your profi ts. Experience the world-class performance of the GE series hobbing machines at www.mitsubishigearcenter.com or contact sales at 248-669-6136.GEseries

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