Gear Technology India 2014 # 1

THE JOURNAL OF GEAR MANUFACTURING

Ask the ExpertCROWNING SPUR TEETHSPECIFYING GEARS TO STANDARDWORKING WITH HIGH-TEMP GEAR MATERIALS

Design and Optimization of Planetary Gears

®

TECHNICAL

IPTEX 2014:Exhibitor Previews

Will the Indian Economy Shake Its Inertia?

GEARTECHNOLOGYINDIA

VOLUME 3 ISSUE 1 - QUARTERLY KARENG04277 FEBRUARY 2014 BANGALORE Free Distribution

Taking Big Gears’Measure

www.geartechnologyindia.com

INsight

GEAR INDUSTRY PROFILEAntonio

Maccaferri

The Power of Knowledge Engineering

Gear up for higher reliabilitywith upgraded SKF Explorer bearingsA robust solution for harsh and demanding gearbox environments, upgraded SKF Explorer bearings enable a gear unit to transmit more torque, sustain higher external loads, or even be downsized to improve cost effi ciency.

In addition, these bearings provide substantially longer life than other bearings. In fact, they have up to twice the rating life of original SKF Explorer bearings, especially under contaminated and poor lubrication operating conditions.

With expertise in bearings, sealing, and lubrication solutions, SKF engineers can add value to the complete gear unit by enhancing reliability and performance, while improving the cost-effectiveness of the complete solution.

For more information, please visit skf.com or contact your local SKF representative.Enhance gear unit reliability and improve performance

Upgraded SKF Explorer self-aligning bearings have enhanced wear and contamination resistance, and are better able to run under tough conditions – up to 100% longer bearing rating life.

www.skf.com

features

technical

26 Ask the ExpertCrowning Spur Teeth“Hot” GearsSpecifying a Quality Gear

36 Design and Optimization of Planetary GearsRobust-design gearboxes for high load capacity and power density.

44 Introduction to BearingsThe ABCs of bearings\

48 The Workhorse of Industry: The Induction Motor

12 IPTEX 2014A sampling of exhibitor offerings to be found at IPTEX.

16 Interview with Antonio MaccaferriCEO dreams big — SAMP — and bigger — Maccaferri Industrial Group.

20 Super-Sized Quality ControlBig gears offer unique inspection challenge.

contents

20

GEARTECHNOLOGYINDIA VOLUME 3, ISSUE 1

16

1VOLUME 3, ISSUE 1 GEAR TECHNOLOGY INDIA

contents

departments


Ask the ExpertCROWNING SPUR TEETHSPECIFYING GEARS TO STANDARDWORKING WITH HIGH-TEMP GEAR MATERIALS

Design and Optimization of Planetary Gears

®

TECHNICAL



GEARTECHNOLOGYINDIA

VOLUME 3 ISSUE 1 - QUARTERLY KARENG04277 FEBRUARY 2014 BANGALORE Free Distribution

Taking Big Gears’Measure


INsight

GEAR INDUSTRY PROFILEAntonio

Maccaferri

06 Publisher’s PageIPTEX 2014: Go For the Weather, Stay for the Gear Show

08 Product NewsNew equipment, software, etc.

50 Industry NewsThe who, what and where

54 Events/CalendarUpcoming shows, conferences, etc.

55 Advertiser IndexAdvertiser contact information

56 INsightCan India’s Economy Get it in Gear?

Photo courtesy of Klingelnberg

GEARTECHNOLOGYINDIA

WESTMINSTER MACHINE TOOLS LTDTel: +44 (0)1572 767922 Fax: +44 (0)1572 768321 Email: [email protected]

www.wmtg.co.uk

Leading supplier of other used:

GEAR MACHINERYSTANDARD MACHINE TOOLS

Call and ask for detailsor visit our website

GLEASON MACHINES AND TOOLING

www.wmtg.co.uk

TOP TOOLS TECHNOLOGY Gear Cutting ToolsPrecision

TOP TOOLS TECHNOLOGY ndAddress: 24/2 Floor,

Indu Ganesh CHS, Trimurty Soc.Rd. Sion- Chunabhatti -East-Mumbai - 400 022. India.

Top Tools is a long experience & established company Producing-Stockiest Complete Range of Precision Gear Cutting Tools since 1990.We specialize manufacture of standard & as per customer requirement

For Various applications

Spline/SerrationSemi-ToppingPre-Grind / Pre- ShavingSprocket / Timing PulleyFine Pitch-Mikron, WormHobRack / Milling Cutter

Gear Hob : Finish /Rough Gear Shaper: Disc / Shank / Hub TySprocket / Timing Spline / SerrationBevel Generating ToolWMW Blade & AccessoriesGear Shaving / BroachesSpline Gauge / Dp-Mod Gauge

Accuracy: AA, A, B, C

In Different Profiles

Mobile: 91-9323115831 91-9820182981 E-mail: [email protected] [email protected]

Telephone: 91-22-234 15831

VOLUME 3, ISSUE 1

2 GEAR TECHNOLOGY INDIA VOLUME 3, ISSUE 1 [www.GearTechnologyIndia.com]

Reishauer AGZürich / Switzerland+41 44 832 22 [email protected]

Gear Grinding in Swiss Precision

Since Reishauer Switzerland invented Continuous Generat-ing Gear Grinding, we have constantly been pushing the per-formance of our machines to new heights: Higher produc-tivity – higher accuracy. That‘s why the leading automotive companies rely on Reishauer.

M/S. Proteck Machinery Pvt. Ltd.Chennai/India+91 44 249 531 [email protected]

Gear Technology India_EN_203x273+3.indd 1 09.01.2014 09:04:16

PUBLISHERSMichael Goldstein, Publisher (USA) & Editor-in-ChiefAnitha Raghunath, Publisher (India)

EDITORIAL STAFFMichael Goldstein, Publisher & Editor-in-Chief,

[email protected]

William R. Stott, Associate Publisher/Managing Editor,[email protected]

Jack McGuinn, Senior Editor,[email protected]

Matthew Jaster, Senior Editor,[email protected]

ADVERTISING SALES (INTERNATIONAL)Michael Goldstein, Publisher & Editor-in-ChiefDave Friedman, Associate Publisher/Sales Manager

DESIGNDavid Ropinski, Art Director,

[email protected]

ADVERTISING SALES (INDIA)Anitha Raghunath, Publisher (India)G. Raghu

GLOBAL SALES AND HEADQUARTERSRandall Publications LLC1840 Jarvis Ave., Elk Grove Village, IL 60007, USAPhone: +1-847-437-6604Fax: [email protected]

INDIA SALES AND REGISTERED OFFICEVirgo PublicationsVirgo House, 250, Amarjyoti Layout,Domlur Extension,Bangalore 560071.IndiaTelephone: +91-80-25357028/29, 41493996/97.Fax: [email protected]

PRINTERSri Sudhindra Offset Process,No. 27-28, 8th Cross, MalleshwararamBangalore 560003Karnataka, India

GEAR TECHNOLOGY® India™ is published quarterly by Virgo Publications, Bangalore (India) under license from Randall Publications LLC, Elk Grove Village, IL (USA). Randall Publications is also the publisher of GEAR TECHNOLOGY® and POWER TRANSMISSION ENGINEERING® magazines in USA. Virgo Publications has been established by one of the promoters of Virgo Communications and Exhibitions Pvt. Ltd., the organizers for IPTEX—the International Power Transmission Expo (a gear engineering event) for the purpose of establishing Indian editions of foreign technical journals.

GEAR TECHNOLOGY® India™ is published in the interest of the members of the gear and power transmission industry in India, to improve communication and further update members of that industry on all the latest developments in the sector. The publishers have made every effort to ensure that the processes described in GEAR TECHNOLOGY® India™ conform to sound engineering practice. Neither the authors nor publishers can be held responsible for injuries or damage sustained while implementing the technology published, which is informatory and not specific.

GEAR TECHNOLOGY® is a registered trademark of Randall Publications LLC, and application for registering GEAR TECHNOLOGY® India™ as is a trademark of Randall Publications LLC is pending. The contents of this publication are Copyright Randall Publications LLC, 2013. All rights are reserved. For permission to reprint any portion of this magazine, contact the publisher at the USA Headquarters office, listed above.

Advertising and subscription information is available atwww.geartechnologyindia.com

GEARTECHNOLOGYINDIA


Ask the Expert: CouplingsCase Depth and Side-Face Carburizing EffectsReal Savings with Synthetic LubricantsOptimal Gear Shaft Manufacturing

Finding and keeping skilled employees


® INDIA

TECHNICAL

INsight

PROFILE: Blaser Swisslube India

20Q213MOTOR

TECHNOLOGY FOCUS

WHO MAKES THE BIGGEST GEARS?

DC MOTOR PROTECTION


Enhanced Induction Hardening of Gears and ComponentsMorphology of MicropittingProgress in Gear Milling

The Involute Curve


® INDIA

TECHNICAL

INsight

HEAT TREAT AUDITDONE RIGHT

PROFILE: Mitsubishi Heavy Industries India

When a Good Gear Drive SystemGoes Bad

20Q113

April-June 2012

INDIA’S GEAR AND POWER TRANSMISSION RESOURCE

Technical•AnalyzingWearinHCRGears• InternalClearanceinBallBearings• Point-Surface-OriginMacropitting•MicropittingofBigGearboxes

INsight•NoSmallMeasure

For Cutting Tools?BIGA

2012FEATURE

POWER TRANSMISSIONCOMPONENTS

INDIA


October-December 2012

INDIA’S GEAR AND POWER TRANSMISSION RESOURCE

Technical•Wear-ResistantBearings•AskTheExpert:ProfileShift

FEATUREMetrology Basics

INsight•HelpWanted

BUYERS GUIDEGEAR MANUFACTURING

MACHINES, TOOLING AND SERVICES

POWER TRANSMISSION COMPONENTS

INDIA



Ask the ExpertCROWNING SPUR TEETHSPECIFYING GEARS TO STANDARD

WORKING WITH HIGH-TEMP GEAR MATERIALSDesign and Optimization of Planetary Gears

®

TECHNICAL



GEARTECHNOLOGYINDIAVOLUME 3 ISSUE 1 - QUARTERLY KARENG04277

FEBRUARY 2014 BANGALORE Free DistributionTaking Big Gears’Measure


INsight

GEAR INDUSTRY PROFILEAntonioMaccaferri

Download them for free atwww.geartechnologyindia.com

Missing Something?All of the back issues of

Gear Technology India are available online.


visit us at the IPTEX:Hall 6Booth D6

machines • tools • processescomplete solution for the gear and profile grinding from one source

further information on our website: www.kapp-niles.com

gear centre KAPP KX 300 P

Flexible system and loading options for your special gear requirements.Roughing and fi nishing in one set-up or machining of several gears in one set-up for fast and precise results.

rotor grinding machine KAPP RX 120

The new and patented roughing process helps to reduce the grinding time by up to 45 %!Integrated in an automated machining cell, fi nished rotors can be deburred concurrent to the machining time.

gear profi le grinding machine NILES ZP 12

Direct drives in the rotary table as well as in the grinding and dressing spindle make the processing highly dynamic.The machine can be operated from the factory fl oor and, as is typical for NILES, is set up without the need for an elaborate foundation.

publisher's page

IPTEX 2014:Go For the Weather, Stay for the Gear ShowThe weather in Chicago lately has been quite miserable. Like many cities throughout the United States, we’ve had one of the coldest and snowiest winters on record. Today it’s fairly warm outside. And by warm, I mean today’s high temperature is about –10°C (14°F), with a wind-chill fac-tor of about –18°C (–1°F).

I would much rather be in Mumbai, where I see today’s tem-perature is a balmy 29°C (84°F). But it’s not just the weather that makes me wish I were there. It’s the gathering of gear and power transmission technology professionals coming to IPTEX 2014.

IPTEX 2014 takes place February 27-March 1 in Mumbai. Now in its third installment, the show has quickly become a central meeting place to learn about the latest technology in gear manufacturing, as well as a terrific event for buyers of mechanical power transmission components. You can read about a number of the exhibiting companies in this issue of Gear Technology India. But to get the full experience, you really have to go to the show. This year, to make it even more worth-while, the event is co-located with GRINDEX, which has a focus on grinding and abrasives technology.

Hopefully the warm weather and IPTEX will combine to gen-erate substantial new business for Indian companies in the gear and power transmission industries. Perhaps things will start to heat up in our industry.

A substantial area of opportunity for Indian manufacturers continues to be exports, particularly now, given that key mar-kets in Europe and North America have stabilized over the past year. If your company’s products have potential demand over-seas and you are looking for the right customers to buy them, then perhaps IPTEX would benefit you. In addition to attract-ing visitors from all around India, IPTEX also attracts key buy-ers from around the globe who are looking to do business with Indian companies.

But if you’re really interested in doing business with North America and Europe, take a look into our sister publications, Gear Technology (USA) and Power Transmission Engineering. Each of these magazines reaches a global audience, heavily concentrated in North America. Depending on your products, advertising in one or both of these could help attract the atten-tion of new potential customers from markets where demand is growing and where your pricing could have significant advan-tages.

If you manufacture products (such as machine tools or cut-ting tools) for use in gear manufacturing industries, please visit www.geartechnology.com/adinfo.htm to learn more about advertising in Gear Technology. If you manufacture mechanical power transmission products (such as gears, bearings, motors, speed reducers, etc.), please visit www.powertransmission.com/adinfo.htm for additional information about advertising in Power Transmission Engineering.

In any case, I wish all of you the best of luck for the coming year. Hopefully IPTEX will help provide the spark that ignites the flames of expanded business in the gear industry.

Publisher & Editor-in-ChiefMichael Goldstein


The LMT Tools Division of the LMT Group has

inaugurated its fi rst state of the Art Global

Manufacturing Facility in India at Chakan, Pune.

Spread over a 3 acre land, LMT India’s

manufacturing facility is in line with the global

standards in terms of aesthetic looks, tech-

niques and technologies being used.

The primary reason behind this expansion is

India’s dynamic and fast growing market,

proximity to customer’s production sites and

the ability to supply the Asian market faster.

This plant will cater to both domestic and

international market needs.

With around 30 of the best quality and latest

machinery in place and 60 well trained em-

ployees, LMT India is inclined towards developing

and producing the best quality and effi cient

tooling systems for the precision tool industry.

This facility will cater to the requirements

from the various industries including automotive

industry, die and mold industry, mechanical

engineering industry, medical technology industry,

aeronautics and aerospace industry.

www.lmt-tools.com

LMT TOOLSGLOBAL MANUFACTURING FACILITY IN INDIA

LMT • THE PERFORMANCE TEAM

LMT India Pvt LtdGlobal Manufacturing FacilityPlot No. A-40/1, Phase I,MIDC Chakan, Village Nighoje,Tal. Khed, Dist. Pune – 410 501.

Phone +91 2135 [email protected]

product news

EMAGFOCUSES ON DIMENSIONAL ACCURACY IN HARDENING

Shorter model life-cycles and increas-ing demands on quality, accompanied by many technological innovations, are driving developments in high-tech industries – such as automotive or aero-space manufacture – ever harder. The effect this has on the production envi-ronment is best shown by the example of hardening. Many of their key com-ponents go through this process at one stage. It is a process that has to be not only highly accurate, but guaran-tee unvaryingly good component qual-ity. It is for this reason that the special-ists at Eldec have committed themselves wholeheartedly to the required standard of reproducibility. Their Mind modular hardening machines stand for exception-al precision and economic processes.

“Reproducibility” is an inalienable word in automotive production. After all, the car as a product is reliant on the unvarying component quality of the drive shaft. In this context, the focus is on the indispensable hardening process. It is well to remember that during this process the component’s micro structure undergoes a change that considerably improves its stability. It is the reason why this key process has to guarantee con-stant reproducibility.

Where Quality MattersThe Eldec experts are very well aware of the fact that the interaction between key components – such as inductors, generators and coolant systems – and a multitude of other components – such as indexing tables, spindle drive and con-trol system – is of the utmost impor-

tance. Over the last three decades, t he c omp any – w i t h he a d qu ar-ters in Dornstetten, near Freudenstadt, Germany – has further developed their hardening technology. And in 2013, Eldec became a part of the EMAG Group. Precision and the integrity of the production process are impor-tant to the Eldec experts, as Dr. Christian Krause, head of application technology, explains, “We are frequently contacted by companies that require their components to be of exceptional quality. We can guarantee this with our system technology.”

At the centre of it is the Mind (Modular Induction) hardening machine, offered in the variants Mind, Mind-M and Mind-S and their different sizes. Generally speak-ing, using modular technology, the machines are configured to suit indi-vidual workpiece dimensions, hardness profiles and production requirements. The modular system ensures that only well-proven components are used. This increases machine stability and guaran-tees that the technology can be offered at an advantageous price-performance ratio. “Engineering of the machine is, of course, greatly influenced by the work-pieces to be hardened,” explains Krause. “Requirements are discussed in detail

w i t h t h e c u s -tomer. This is fol-lowed by the grad-ual assembly of the Eldec Mind sys-tem, selecting the required key com-p o n e nt s : b a s i c machine, energy source, inductor, coolant system and – where required – the automation components.”

High Efficiency, Precision DosingFor every machine component, the machine builder relies on quality details and the accumulated know-how. The result is a machine that considerably improves the economic viability of the process.

Example: Basic machine. The base is constructed of massive, high-precision welded components and includes the main column for the z-axis. The vibra-tion-resistant construction ensures great machining accuracy. Depending on the clamping system used, Eldec machines can accommodate workpieces of up to 1,200 mm diameter.

Example: generator. Available are micro-processor controlled single- or dual-frequency generators with a capac-ity of five to 3,000 kW. They are highly efficient and allow for the required ener-gy to be adjusted with great precision. Their performance also adjusts itself automatically, and with equally great precision, to that of the inductor used.

Example: inductor/tools. These are manufactured according to customer specification, using 3D-CAD software. They are of micrometric accuracy and made with the help of state-of-the-art machinery and experienced staff.

Even the simplest performance data of the Mind technology from Eldec is bound to impress. For instance, a driv-ing pinion is processed in as little as 14 seconds. The component is inserted into the indexing table of the machine either automatically (for instance by robot) or


manually. Depending on the workpiece, the hardening process takes between 100 milliseconds and a few complete seconds. After quenching, the hardened steel is gradually tempered. The machining cycle is completed with the subsequent cooling process. “Of decisive importance to us is not just the enormous speed of the pro-cess, but also the precision of the hard-ening operation,” explains Krause. “For instance, on Eldec machines the variation in effective hardening depth is no more than ±0.1 mm – an extremely low value when it comes to hardening.”

Benefitting from the General TrendsWith this background, it is hardly sur-prising that Eldec is benefitting from the general trends in the automotive and aviation industries. The geometries of many components are becoming more complex and, at the same time, the pieces tend to get smaller. The harden-ing process has to keep pace with this development and guarantee the required quality despite more demanding basic conditions. With their Mind series of machines the Eldec machine builders

have even lent more flexibility to the workflow by providing a suitable degree of automation. Their machines are now available in versions ranging from man-ually loaded stand-alone solution to fully integrated in-line hardening cells for the soft and hard machining of components.

It is in the emerging markets in Asia in particular, where the highly flexible use of these machines scores heavily. Here, large automobile manufacturers put their faith in Eldec machines when they are building their new production

facilities. “In China, for instance, the production quality of components has to be on par, in every respect, with that in Europe or the United States. And we offer the hardening machine technol-ogy they need. It is a technology that impresses with its economic processes,” concludes Krause.For more information:EMAG Holding GmbHPhone: +(49) 0 7162 17-267www.emag.com

MIKRON DMG | DISKUS TBT | HELLER ELB | NAGEL SCHAUDT KEHREN KARSTENS MIKROSA INDEX | ZEISS BOEHRINGER GILDEMEISTER SCHÜTTE AGIE | SCHULER

Gear cutting machines:

LORENZ | HURTH PFAUTER | KAPP KOEPFER | NILES LIEBHERR REISHAUER LINDNER KLINGELNBERG GLEASON WMW

www.geiger-germany.com

HANS-JÜRGEN GEIGERMaschinen-Vertrieb GmbH

Metzingen/Stuttgart

High quality used machine tools from Germany since 1968.Please visit our showrooms: 7000 sqm display area with more than600 machines in best condition.

HANS-JÜRGEN GEIGER Maschinen-Vertrieb GmbHJames-Watt-Straße 12D-72555 Metzingen (Germany)Phone +49 (0)7123 /18040 Fax +49 (0)7123 /18384E-Mail: [email protected]

b-w

erk.

de


product news

BurriRETROFITS REISHAUER GRINDING MACHINES FOR GEAR MARKET

Burri Werkzeugmaschinen GmbH Co. KG was founded in 2003 and has emerged as a world leader in the new grinding wheel dressing machines and in retrofitting the Reishauer gear grind-ing machines. According to Burri, the gear grinding machine after recon-struction is technically at par with a new machine and has an unbeatable price-performance ratio. Burri GmbH offers a 12-month warranty and a CE Declaration of conformity like a new machine.

A typical retrofitted machine evolves through the following process: The old machines are completely dismantled, mechanically reworked and repainted. All scraped guides are replaced by stan-dard linear guides and retrofitted with ball screw spindles and Heidenhain measuring systems.

The grinding support holds a direct drive from the grinding servo motor to the grinding spindle, thus eliminating the mechanical troubleshooting compo-nents. The machine is fitted with a new profiling slide and dressing unit with water-cooled, speed-adjustable, built-in dressing spindles. The four measuring systems on the newly built dressing unit help the operator to store the set values and reduce the setup time.

The workpiece spindle is designed as a water-cooled direct drive, thus elim-inating the wear and tear of the gear box. The movement of the work slide is changed from hydraulic to servo move-ment. A new tailstock

with quill preload in the control is also included.

The machine receives a completely new control system with compact flash card on which hundreds of gear pro-grams can be saved including USB inter-face, remote maintenance for trouble-shooting and software update, dialogue guided user interface. All drives are equipped with water-cooled digital con-trollers with network recovery and servo motors.

The new state-of-the-art control from B&R Automation has reduced the cabi-net to a quarter of the original size. The hydraulics are only used for workpiece clamping and A-axis clamping. The machine hood, hydraulics and the elec-trical cabinet are fixed to the machine and can be transported without dis-mantling. The Acopos multi-drive sys-tem achieves very good energy efficien-cy and reduces the power consumption nearly to one third. The machines now have the advantage of auto fine balanc-ing and a single centering system for the entire module range coupled with an automatic adjustment of the cen-tering probe. The tooth flanks can be corrected on profile and lead through a user friendly software. The machine has been designed to reduce cycle and setup time. With the new control, the machine is very flexible and well suit-ed for small, medium and large series. Burri India Pvt Ltd is a subsidiary unit of Burri Werkzeugmaschinen GmbH &

Co KG and supports sales and service in India.

For more information:Burri India Pvt [email protected]

www.burri.de

IgusEXTENDS SELF-ALIGNING BEARINGS LINE

P l a s t i c b e a r i n g expert Igus will be presenting their l ine of detect-able self-align-ing bearings for the food industry. The detectable bear-ings are an extension of the Igubal self-align-ing bearings line from Igus, which includes a range of lubrication and maintenance-free rod-end bearings, clevis joints, flanged units, press fit and pedestal bearings. Both the housing and spherical ball are detectable by standard metal-detection systems to pick up even the smallest particles of the bearings were failure to occur. The bearings are easy to install, adjust to all angular mis-alignments, and can replace tradition-al metal bearings, which can weigh up to 80 percent more than Igubal. Igubal detectable bearings are dry-running, unaffected by dirt and dust, operate well in liquids and a variety of chemicals, and are corrosion resistant. They are suited to run in temperatures from -40º - 176ºF, and are able to absorb very high forces due to their vibration-damping prop-erties. They also possess high levels of compressive strength and elasticity.For more information:Igus (India) Pvt. Ltd.Phone: +(91) 80-45127800www.igus.in


SKFRELEASES CARB BEARINGS FOR STEEL MILLS

SKF Carb toroidal roller bearings intro-duce robust non-locating bearing solu-tions engineered to withstand the tough operating conditions encountered in a wide range of rotating machinery appli-cations in steel mills. These self-aligning bearings designed for radial loads exhibit very high load-carrying capacity, high running accuracy, low friction, and resis-tance to wear, resulting in reduced noise and vibration and promoting improved reliability and longer service life. Typical steel industry applications for these bear-ings include casters, large electric motors, gearboxes, fans, and others where non-locating bearings must be specified.

A Carb bearing (for radial loads only) in the non-locating, or “float,” position in combination with a spherical roller bear-ing (for combined axial and radial loads) in the locating, or “held,” position ulti-mately can deliver a highly efficient bear-ing arrangement to eliminate the influ-ence of shaft contraction or expansion due to temperature fluctuations often associated with steel mill applications.

Carb bearings integrate design fea-tures from several conventional bear-ing types to realize opti-mized capabilities and performance. They can accom-modate misalign-ment (similar to a spherical roller bearing), adjust for axial expan-sion of a shaft (similar to a cylin-drical roller bear-ing), and maximize load capacity due to long, self-guiding rollers (similar to nee-dle roller bearings).

All Carb bearings have further been upgraded to the SKF Explorer perfor-mance class characterized by high-qual-ity steel and an improved heat treatment process to impart superior hardness and toughness for operation in the most dif-ficult conditions.For more information:SKFPhone: +(46) 31 337 10 00www.skf.com 11VOLUME 3, ISSUE 1 GEAR TECHNOLOGY INDIA

feature

Gleason Corporation

Booth # P3Gleason will introduce its latest Analytical Gear Inspection System, the 300GMS, along with advanced tooling and global customer support services at IPTEX 2014. On display in Booth P3 will be:

The Gleason 300GMS Analytical Gear Inspection System: For the complete inspection of automotive transmission gears and other smaller gears, gear cutting tools and non-gear parts. This latest addition to the GMS Series of inspection sys-tems (with models available for gears up to 3,000 mm in diameter) – was developed specifically to meet the needs of the world’s leading automotive, aerospace and other like-size gear producers for a faster, more economical solution for complete gear and even non-gear parts inspection. It is the first GMS to feature the new Windows 7-based Gleason GAMA 3.0 applications software suite which, like its GAMA 2.0 prede-cessor, offers users a highly intuitive user interface and simple input screens for programming of workpiece and cutting tool data. Those features, combined with ease of setup, a .NET con-trol system, and movement optimization, reduce the cycle times required for the complete inspection of almost any gear or gear tool. The 300GMS also features a Renishaw 3-D probe head to provide maximum accuracy and flexibility for the complete inspection of all kinds of gears and gear-cutting tools and, in particular, finer pitch gears.

The 300GMS is equipped with new ergonomically mounted operator workstations and an Advanced Operator Interface – both designed to greatly improve the operator’s effectiveness at every stage of the inspection process. The Advanced Operator Interface puts a number of powerful tools right at the opera-tor’s fingertips, including a ‘weather station’ to record temper-ature and humidity, and video telephony, note pad and voice mail messaging capability, enabling the user to capture video, describe a particular programming issue and transmit it over the web to others in the customer’s organization or to Gleason for support. In addition, the 300GMS, like all the systems in the

GMS family, offers users the ability to meet a variety of inspection tasks beyond just gear geometry on a single platform, including surface finish and form measurement and even prismatic (CMM) measurement.

Visitors to Gleason Booth P3 will also have the opportunity to learn more about our local production of advanced Genesis Hobbing Machines, workholding and cutting tools along with our state-of-the art cutting tool re-sharpening and re-coating capabilities. They will also be introduced to a number of other significant products, technologies and services, including: a complete line of gear cutting solutions, advanced workhold-ing solution, Gleason Global Services and the Gleason Connect Remote Service technology, which enables Gleason service spe-cialists from anywhere in the world to quickly and cost effec-tively identify, diagnose, repair and monitor products, minimiz-ing costly downtime.For more information:Gleason Works IndiaPhone: +(91) 80-2852-4376www.gleason.com

IPTEX Exhibitors PreviewIPTEX 2014, the third International Power Transmission Expo, is dedicated to the gear and power transmis-sion industries. India is rapidly turning into a global manufacturing hub, thanks to the country’s manu-facturing and engineering capabilities, vast pool of skilled expertise and its size. These qualities offer it a strategic advantage for the manufacturing segment. A large number of international companies in varied segments have already set up a manufacturing base in India and others are following suit. Here’s a run-down of some of the booths attendees should make sure to visit during their time at IPTEX 2014.


Stresstech GroupSince 1983, Stresstech Group (from the foundation of American Stress Technologies, Inc.) has served the metal industry all over the world with solutions and high-tech instruments for non-destructive testing of the quality of components. Stresstech Oy- Finland (head office and manufacturing facili-ty), American Stress Technologies, Inc. (AST) - USA, Stresstech GmbH- Germany & Stresstech Bharat Pvt. Ltd- India form the Stresstech Group. Stresstech Bharat Pvt. Ltd. (SBPL) is a fully owned Indian subsidiary of Stresstech Oy Finland and is the group’s authorized service centre in India.

The main products that will be presented during IPTEX 2014 include:

Barkhausen noise analyzers, sensors and custom inspection stands. Barkhausen noise is utilized to study magnetic proper-ties and thus the presence or absence of material defects and residual stress levels in various components like gears, bearings, camshafts, crankshafts, universal joints, piston pins, etc.

X-ray diffraction analyzers and inspection stands. X-ray ana-lyzers use X-ray diffraction to measure residual stresses and retained austenite contents.

Residual stress testing instrument based on hole-drilling. The Prism system is based on hole-drilling technique for measuring residual stresses.

In short, this equipment is used for studying: grinding burns, heat treat defects, hardness changes, residual stresses, retained austenite contents, etc. or for controlling the quality of: grind-ing, heat treating, shot peening, machining of camshafts, crank-shafts, ball bearings, gears, valves, rotors, turbine blades, cylin-der blocks, cylinder heads, etc. As per customer’s requirement, the company can supply manually operated, semi-automatic and fully automatic non-destructive testing (NDT) equip-ment. They also serve to all types of metal industries by offering residual stress and retained austenite measurements with X-ray diffraction and Barkhausen noise analysis in addition to the equipment for sale.For more information:Stresstech Bharat Pvt. Ltd.Phone: +(91) 22 2500 1047www.stresstechgroup.com

KISSsoftBooth # A8

“India is a key market both in terms of supply and demand, paired with a good overall design capacity and a deep interest of the involved engineers in the funda-mental theories. Hence, the need for and the interest in top level gear design software is very strong in India, possibly stronger than in any other emerging market,” says Hanspeter Dinner, managing director at KISSsoft. “KISSsoft has been answering this need for the last ten years. It is used by the leaders in two wheelers, cars and trucks, agricultural vehicles, industrial gearboxes and aerospace industry, be it for private entities, universities or government/defence establishments. Regular train-ings and an experienced local support team ensure that the customers can benefit most from their investment in the software.” Dinner notes a particular interest in their system software KISSsys, as the Indian engineers tend to look at the design process in a holistic manner, preferring to start their work on a system level. “Recently, the highly detailed loaded tooth con-


feature IPTEX EXHIBITORS PREVIEW

tact analysis has created excitement as the Indian gear industry has been moving away from low tech to high tech products with increased power density. We also observe a shift from worm gears that have been very popular in India for a long time to more efficient planetary gears. Here, the dedicated planetary modules in KISSsoft, includ-ing fine sizing function for planetary sets and the loaded tooth contact analysis for planetary systems, are of great interest. We strongly believe in this market, it has been one great success story and we are dedicated to tailor the KISSsoft software also to the Indian gear engineer’s needs,” he adds.For more information:Kadkraft Systems Pvt. Ltd.Phone: +(91) 20 30461527www.kadkraft.com

Drake Manufacturing Services Co.Booth # A21

Drake Manufacturing Services Co. designs, builds and services state-of-the-art, precision CNC manufacturing systems for parts with form, index and helix such as threads, worms, gear teeth and racks. Drake provides machine solutions in the steering systems, power transmission, speed reducer, cutting tool, ball screw, linear motion and aerospace industries. The company recently announced the expansion of its local India support team. G. Rajasekhar Reddy will be on-hand at the Drake booth during IPTEX. Reddy has more than 20 years in the machine tool industry and has experience in thread gear and worm grinding requirements. Drake’s estab-lished sales and service support continues with VMT Technologies in Bangalore.For more information:G. Rajasekhar ReddyPhone: +(91) 98 4527 8216www.drakemfg.comVMT TechnologiesPhone: +(91) 98 4405 [email protected]

Shanthi GearsShanthi Gears is the unique gate-way to a wide range of power

transmission prod-ucts which includes gears, gearboxes, geared motors and

gear assemblies both standard and cus-tom-made. With headquarters at Coimbatore, South India, they are in the business of designing, manufacturing and supplying various kinds of gears and gearboxes to almost all industries and applications for the past four decades. Market leaders in seg-ments including abrasives, auto components, cycles, sugar, farm inputs, fertilizers, plantations, bio-products and nutraceuticals, the group has forged strong alliances with leading internation-al companies like Groupe Chimique Tunisien, Foskor, Cargill, Mitsui Sumitomo, Morgan Crucible and Sociedad Química y Minera de Chile (SQM). The Group has a wide geographical

presence spanning 13 states in India and five continents. Shanthi acts as consultants in the field of engineering design, advisors and purveyors of technical know-how and applied technology, solution providers and business process outsourcers in the field of engineering design and drawing, software programming etc.For more information:Shanthi GearsPhone: +(91) 422 [email protected]


SFH 160/250 CNC

www.gearspect.com

Horizontal Gear Hobbing machine

Horizontale CNC-Wälzfräsmaschine

6- axes CNC controlled horizontal gear hobbing machine with excellent dynamic property,for precision gearing and having ability to machine helical gear up to 70° helix angle.

Horizontale, CNC-gesteuerte 6-Achsen-Verzahnungswälzfräsmaschine.Die moderne mechanische Bauweise gewährleistet ausgezeichnete dynamischeEigenschaften der Maschine bei der Anwendung leistungsstarker Werkzeuge bis 70°.

SFH 160 CNC SFH 250 CNC

Max. Diameter of gear / Max. Raddiameter 160 mm 250 mm

Max. Module / Max. Modul 4 mm 6 mm

Max. Helix angle β (*OPTION) / Max. Neigungswinkel β (*OPTION) ± 45° (* ± 75°)

Max. Clamping length / Max. Klemmlänge 800/1250/2000/3000 mm

gear profile

Q: What are the keys to success for a family-run business now in its third generation, operating on a global scale?

A: SAMP is in fact only a part of the family business, the Maccaferri Industrial Group, which is an international company boasting a rich portfolio of activities rang-ing across the widest of sectors, from environmental engineering solutions to real estate and con-struction, from the food industry to tobacco, going through bio-technologies and the field of renewable sources of energy. One of the main keys to success can be found in the fact that our Group has always relied on a strong team of experienced man-agers and high-skilled profes-sionals specialized in their own field, whereas family members take care of the strategy and co-ordination.

Q: How has the gear industry evolved since you took over as President in 1995?

A: Surely the indus-try has dramati-cally changed, especially as far as internation-alization and diversification on a global scale are concerned. For example, when I started in 1995 nobody could imagine that China would grow in such a spectacular way, to the point that today SAMP has three manufac-turing plants in Shanghai, one for each business unit of the com-pany (Samputensili, Sampsistemi and Sampingranaggi). Another important effect of the globalization was represent-ed by the huge opportunities offered by the North American market. For this reason, in 2002 Samputensili started a strate-gic partnership with Star Cutter Company through the creation of the joint-venture Star SU LLC, the sole go-to-market organiza-tion based in Hoffmann Estates, IL, responsible for the sales and distribution of cutting tools and machine tools technology for the North American market.

Q: What are your goals for SAMP in both the near-term and long-term with regard to being a sup-plier to the worldwide gear man-ufacturing community?

A: We have always followed a glob-al, international approach both as a company and as an industrial group. Our main goal has always been the satisfaction of our cus-tomers’ needs with high profes-

sional skills, capacity and quick actions driven by our will to con-stantly improve. By doing this, we have always worked hard in order to be close to our customers as a reliable manufacturing company, pro-viding them with the support and service they need in a fast and comprehensive way. This approach had led us through the decades to the creation of a broad network of manufactur-ing facilities, such as the one in Brazil in 1974, the one in South Korea in 1995, the creation of our American joint-venture Star SU in 2002 and of a Chinese joint-venture between Samputensili and STW in 2005. This has always been our philosophy and we will certainly continue to do so also in the years to come.

Q: What do you see as your major challenges in both the near and long term, both as a company and as a manager?

A: Our major challenges will be represented by the continuously evolving technology, the ever

GEAR SAMPLE:INTERVIEW WITH

ANTONIO MACCAFERRI


growing competition amongst machine tool manufacturers and gear cutting tool manufacturers, as well as the features and new technologies that are specific to each market in which we are present and to each market that we serve. These are and will con-tinue to be our major challenges both in the near and in the long term.

Q: What regions of the world are showing the most promise for growth for SAMP in gear manu-facturing and why?

A: We are closely following the evolution of China, South-East Asia, Brazil and South America in general. Of course, in terms of volume, Europe and the United States remain our most important markets for high-quality gears and gearboxes, supplied by our business unit Sampingranaggi, and we expect these areas to recover very short-ly.

Q: What innovations, changes or trends do you see in the coming years that will impact the world-wide gear manufacturing com-munity?

A: The innovations we are expe-riencing around us are not real revolutions. More than anything else, we are seeing production centralizations, large companies merging together, especially in the automotive sector, and we believe that the average size of corporations in the future will continue to grow.

Q: What are your goals for SAMP over the next five years? Do you have any plans on expanding in the near future, outside your existing operations?

A: We will surely strive to remain among the market leaders and further increase our market pen-etration in those segments where we still are not a reference brand. At the moment we do not foresee the opening of new manufactur-ing plants, but we are working towards the creation of new sales

THE HISTORY OF SAMPBY ANTONIO MACCAFERRI

The history of SAMP and its brands has always been eventful, and it represents a perfect example of company verticalization. At the end of the 19th century, in Casalecchio di Reno near Bologna, Italy, my grandfather’s uncle began to use wire mesh to assemble gabions (boxes filled with rocks, concrete, or sometimes sand and soil) to repair dams destroyed by floods of the river Reno. At the beginning of the 20th century, he purchased a pat-ent for a new type of wire mesh box gabion and started the industrial production of gabions for civil engi-neering use.

As a consequence, in 1936 Gaetano Maccaferri, my grandfather, started out with a small workshop for the production of wire machinery. The production included wire drawing machines, looms for weaving metal-lic meshes and general mechani-cal parts. He called his company S.A.M.P., which translates from the Italian as “Company for Precision Metalworking.” Since it was difficult to find good quality gears at that time, he started manufacturing his own.

During the Second World War, SAMP supplied the Italian air-force with precision gears, but the demand-ing quality requirements forced the company to produce its own high-precision gear cutting tools. For the same reason, the company was later to start developing its own tool grinding machinery, manufacturing equipment that set the standard at those times.

With a wide range of quality gear cutting tools on board by 1949, SAMP decided to establish Samputensili, an ad hoc structure and trademark through which to trade these products. In the years that followed, this new company was to grow into a worldwide sup-plier of gear cutting tools and, later, also of grinding machines for cylin-drical gears, shafts, worms, rotors and screw threads.

The second spin-off of SAMP, Sampingranaggi, came into being in 1973, extending the compa-ny’s gear production program to include bevel gear sets and high-precision gearboxes. Before long, Sampingranaggi was able to sup-continued on page 39


gear profile ANTONIO MACCAFERRI

and distribution offices in India and in South-East Asia.

Q: How have your customers’ demands changed in recent years? What is SAMP doing to accommodate those demands?

A: Our customers are becoming more and more price-sensitive. In addition, we have experienced an increase in the request for technical support and production optimization, as a consequence of the internal restructuring that many companies have carried out over the past few years. In order to meet these needs, we have established new sales and technical capacities and have further expanded our network. In our main markets we are local-ly present with manufacturing plants to supply our customers with fast, reliable and excellent sales and after-sales service.

Q: Tell us about your North American distribution, sales and service oriented representation.

A: SAMP S.p.A. and SU America have a strategic partnership with Star Cutter Company through Star SU LLC (Hoffman Estates, IL) to sell our machine tools, gear cutting tools and tool services under the highly visible Star SU brand in North and South America. Star SU

is supported by 30 direct region-al sales managers and eight ser-vice engineers. Our partnership with Star started in 2002 and was further extend-ed in 2013 to include not only the sales organization, but also the manufacturing plants in the United States, the service center in Mexico and the Samputensili plant in Brazil.

Q: What do you see as your major challenges as a supplier to the gear industry?

A: We are challenged to supply a broader range of support activi-ties within customer facilities. We are managing this by extend-ing full product support and manufacturing support activities with Star SU on-site engineers. Though challenging, this is a tre-mendous opportunity to supply these services as an added value proposition at a reasonable cost.

Q: Do you have any concerns regarding recruiting and retain-ing skilled workers in your work-force?

A: In manufacturing, we are faced with the great challenge of mak-ing our business attractive to young, skilled engineers and technical people. This involves a great commitment to promote

and educate potential employ-ees by our company and private industry, but it must also work in cooperative partnership through universities and high schools. Once we have recruited these young workers we need to have the right training available to them and growth plans in place to keep them.

Q: Are there any other subjects you would like to talk about?

A: SAMP is known to the world mar-ket not only for its high-quality and reliable gear manufactur-ing tools, but also for its wide range of grinding machines. At Samputensili we began produc-ing machine tools some 50 years ago to improve the manufactur-ing quality of our gear cutting tool range. In particular, our horizontal grinding machines are amongst the finest machine tools for gear, rotor and screw manufactur-ing in the world. Our experience stems from our own manufactur-ing needs in terms of prototyp-ing and in-house job shopping. Know-how matured in such a way has flowed directly into the end product, and this is what dis-tinguishes our solutions from the rest. Our machines are extremely flexible and allow customers to


ply both single components and finished gearboxes.

In 1997 SAMP’s wire drawing machinery division took the name of Sampsistemi and, thanks to the acquisition of competing compa-nies, it broadened its portfolio to include extrusion equipment for the manufacture of finished cables.

In 2000, with the acquisition of the former Modul company based in Chemnitz (Germany), Samputensili added hobbing technology to its manufacturing program, becoming one of the few players in the world to offer a complete gear manu-facturing program, covering both roughing and finishing operations.

In 2002 Samputensili started a stra-tegic partnership with Star Cutter Company through the creation of the joint-venture Star SU LLC, the sole go-to-market organiza-tion based in Hoffmann Estates, IL, responsible for the sales and distri-bution of cutting tools and machine tools technology for the North American market.

In 2006 Samputensili, Sampsistemi and Sampingranaggi merged to form SAMP S.p.A, a new holding company which put together the three macro-sectors of its business:

• Samputensili, global provider of complete solutions (machine tools, tools and services) for the production of gears;

• Sampsistemi, manufacturer of machines and systems for wire and cable production;

• Sampingranaggi, specialized pro-ducer of high-quality spur and bevel gears as well as complete gearboxes.

Each of the three business units has its own technical department, sales force and after-sales service, where-as corporate services like human resources, procurement, IT, finance and administration are shared among the three divisions.

In 2009 SAMP moved to a brand new plant in Bentivoglio (Bologna), Italy, which integrates all European manufacturing sites of the three divisions in one modern, state-of-the-art plant.

For more information:Star SU, LLC5200 Prairie Stone Parkway, Suite 100Hoffman Estates, IL 60192Phone: (847) 649-1450Fax: (847) [email protected] Industrial Groupwww.maccaferri.itSAMPwww.sampingranaggi.comwww.sampsistemi.comwww.samputensili.com

use both ceramic grinding tools and electroplated CBN grinding wheels. Therefore they represent the ideal solution both for pro-totyping/small batch production and for high-volume gear manu-facturing.

For more information:Star SU, LLC5200 Prairie Stone Parkway, Suite 100Hoffman Estates, IL 60192Phone: 847-649-1450Fax: [email protected] Industrial Groupwww.maccaferri.itSAMPwww.sampingranaggi.comwww.sampsistemi.comwww.samputensili.com

continued from page 37


feature

SUPER-SIZED Quality ControlA Guide to Improving Big GearsMatthew Jaster, Senior Editor

It’s not easy being big. Maybe that’s not exactly how the phrase goes, but it’s applicable, particular-ly when discussing the quality require-ments of large gears. The size alone promises unique engineering challenges. Those involved in producing large gears continually strive to meet higher qual-ity requirements, adapt to new testing methods and seek out ways to top their own manufacturing capabilities. Seems an awful lot needs to go right in order to achieve the quality requirements neces-sary to survive in the big gear business.

“In-shop inspections are mandatory,” says Fabrice Wavelet, product line man-ager, Ferry Capitain. “No customer can afford to put a gear into service that is

not 100 percent sure/sound. A mining company, for example, can do nothing without a functional driving system on its mill, as 100 percent of the ore is going through it. Failure is not acceptable.”

“The quality of large gears takes tech-nical expertise, years of experience and proper equipment,” says William Quinn, business development lead, mill prod-ucts at Rexnord. “Improvements in materials, lubrication and gear quality levels have made positive impacts in the life of today’s large gears. Modern gear cutting and grinding machines need to be met with equally advanced geometric inspection equipment.”

“With higher accuracies of the gearing we can extend the lifetime of the equip-

ment,” says Holger Fritz, product manag-er mill gearing, Hofmann Engineering. “To be able to determine higher quali-ties, the measuring equipment has to be a minimum of one accuracy level high-er than the item that is being inspect-ed. This is a challenge for the future and we’re working hard to improve the inspection methods and one day might have a minimum big gear (above eight meters) quality level of AGMA 12.”

“While it’s always good to improve the quality of large gears, the current require-ments are already impressive thanks to ASTM A609 and ASTM E709 or E1444,” adds Wavelet. “The same requirements for a 3 m gear and for a 10 m gear makes the 10 m gear of a comparatively higher

Photo courtesy of Rexnord


quality, simply because casting such a heavy part (more than 20 tons a segment, finished weight) has nothing to do with casting a 3-ton segment.”

Tools of the TradeWhat’s the best way to inspect these large gears? According to our big gear experts, it’s a combination of many dif-ferent tools.

“Hofmann Engineering is using laser trackers for the dimensional inspection on big mill gears and portable CMM arms to determine the form on the invo-lute and the lead line,” Fritz says. “For the pitch we use a special D&P pitch tester. But the ultimate test is still the mesh test of a precision ground mill pinion that is measured on a CMM together with the mill gear. Mill pinions are always mea-sured on a gear CMM machine.”

He adds that before they even start machining at Hofmann they use ultra-sonic units and magnetic particle units to determine the quality of the material or of the welds.

“Varying challenges exist depending on the inspection required; in-process non-destructive inspections can be done with relative ease in the manufacturing envi-ronment. Once the gear is in operation, the same type of nondestructive testing can take a significant amount of time—from a couple hours to multiple days. Usually this involves shut down, remov-ing guarding, and cleaning the area to be inspected of lubricant,” Quinn says.

Other operational inspections can be completed continuously or with ease, such as vibration monitoring, lubrica-tion testing, and infrared temperature monitoring,” says Quinn. “In-process non-destructive testing is done primar-ily with magnetic particle inspection and ultrasonic inspection. Complex geom-etry in large gears can present challenges to ultrasonic inspection, but with skilled technicians and control processes we can overcome these.”

For field inspections, infrared ther-mometers and cameras, and multi-axis vibration monitoring equipment with read out capability make continu-ous monitoring relatively straightfor-ward. “More in depth field inspections of the gear may involve using a MAAG TMA gear checker to check pitch, mag-netic particle inspection with a hand

yoke, and standard ultrasonic inspection equipment,” Quinn adds.

“The development of UT Phased Array and of Eddy Current (classical or Phased Array) is of the highest interest for us. These techniques have been successfully used on site, allowing an interesting time saving compared to the classical meth-ods, but they are not economical on large surfaces and in-process inspections … for the moment,” Wavelet says.

“The question regarding the most use-ful inspection can’t really be answered as all the above mentioned inspections are necessary to prove that we manufactured a top quality gear,” Fritz adds.

Why are so many different inspection requirements necessary for big gears?

“The size of the items in question,” Fritz says. “Temperatures for example have a big impact on the final sizes and a temperature controlled environment is necessary.”

Also, large gears today imply large module and consequently, large rim thickness, particularly when talking about foundry. “I suppose it is the same thing with forgings or plate; the main challenge is to maintain the high qual-ity level required into such parts. For a gear module 36 in cast steel (something that was exceptional 10 years ago and usual today), the as-cast gear rim is eas-ily wider than 220 mm, considering both the machining stock and the riser defor-mations. Avoiding internal indications as small as 5 cm² in this outer rim is the highest challenge a foundry is confront-ed with today,” says Wavelet.

Such defects have to be avoided or the foundry undertakes the risk of having the part rejected.

“This is where the experience and the knowledge come into the equation, whether the gear is in steel or in ductile iron. The number of foundries capable of doing small gears (i.e. 3 m) in cast steel or ductile iron is high throughout the world. The number of foundries capable of producing the largest and most power-ful gears today can be counted on the fin-gers of one hand,” Wavelet says.

Although size matters, the inspection techniques (ultrasonic or magnetic par-ticle) are identical for small and large gears… as well as the quality require-ments.

“These techniques are reliable and repeatable when used by qualified per-sonnel. The type of products being made for narrow markets use in-house inspec-tion people. This is what we do in Ferry Capitain. All our inspection personnel are qualified ISO 9712 / Cofrend level 2 (at least equivalent to ASNT level 2) for UT, MPI, dye penetrant test and radiog-raphy, although these two last techniques are not commonly used on gears. Use of classical techniques, rather than the UT Phased Array, for example, is still jus-tified as this saves time in production, while the equipment is economical. We believe at Ferry Capitain that the new techniques, including UT Phased array, are of the most interest, but for expertise, not production control,” Wavelet says.

“Magnetic particle inspection is still the industry standard for checking sur-

Photo courtesy of Hofmann Engineering


feature SUPER-SIZED QUALITY CONTROL

face discontinuities; it is widely used and acceptance criteria are clearly defined by manufacturers and industry standards,” adds Quinn. “Ultrasonic inspection is the accepted method for checking sub-surface discontinuities. Continuous tem-perature monitoring, lubrication test-ing, and vibration monitoring are still the most beneficial inspections that can be performed in the field. Monitoring these parameters over time and track-ing deviations from baseline readings quickly allow a user to identify potential problems.”

One wonders how much time these techniques take from a quality control perspective.

“It really depends on the type of inspection being performed. In-process ultrasonic testing of our largest ring gears can take up to 7 hours; magnetic particle inspection of the teeth can run up to 3 hours per segment,” Quinn says. “Field inspections consisting of con-tact checks and root clearance measure-ments can take from 4 to 8 hours. More involved inspections are usually sched-uled during planned shut downs and can last from a couple days to a week plus.”

Big Gear StandardsOne area that continues to play a vital role in the inspection process is the gear standards. Whether it’s AGMA, ISO, DIN or any others, they need to be

updated and modified regularly to keep up with demand.

Fritz at Hofmann Engineering believes AGMA standards cover most of the inspections. “It would be good if they would have chapters about mesh test results, surface finishes and gen-eral guidelines for dimension tolerance. As a gear designer/manufacturer you know all about these things, but most third-party inspectors want to have some documentation/recommendation of an AGMA standard referring exactly to these points,” Fritz says.

“AGMA 6014, and especially the next version, which should be issued sometime next year, addresses all the inspections and quality requirements large gears need to respect. We, at Ferry Capitain, have developed an intensive R&D program on materials and defects with the aim to be able to quantify the influence of surface or internal defects on the service life,” Wavelet says. “The number and concentration of indica-tions do not matter to us as one defect is enough to ruin a complete gear and compromise the driving function of it. Then, the size of a unique defect, and its location, are the parameter to be con-sidered. A better understanding of the nature of the defect and its influence on the service behavior is what we are working on today.”

Quinn at Rexnord agrees that the standards work but tweaks are in order.

“AGMA 6014 addresses magnetic par-ticle, ultrasonic, as well as geometric inspections required during the process-ing of large gearing. The annex contains essential operational inspections and recommended frequency for large gears, recommending lube analysis, vibration monitoring, infrared alignment, visual inspection, gear joint tightness, pictures, contact pattern and root clearance. (But) the AGMA standard does not directly address nondestructive field inspection of ring gears,” Quinn says.

Pushing the Technology ForwardWhat’s next for inspecting big gears? What can the industry look forward to in the near future? Hofmann, Rexnord and Ferry Capitain all have ideas. The technology and the machines will grow, according to Fritz.

“I know of an eight-meter machine so far but I know that there are plans to build bigger machines. The challenge of big gear measurements will be to measure the much tighter tolerances of AGMA 12 or 13 on 15 m gears,” Fritz says.

“The development of computer-assist-ed are not economically viable for in-shop inspection and for Eddy Current. It is thus probable Eddy Current will take over MPI in the close future, as this technique is easy, fast and reliable. As for

Photo courtesy of Rexnord


UT Phased Array, the only question that inspection equipment manufacturers have to solve is the question of probes: they have to be reliable, economical and adaptable to all kinds of materials, sur-face finish and size,” Wavelet says.

“Improvements in continuous moni-toring system analysis will offer faster indication of distress, helping plant per-sonnel to make necessary adjustments and avoid costly downtime. Condition monitoring/analysis systems allow the user to identify a problem in one area before it has an adverse effect on equip-ment in another. Eddy current inspec-tion is likely to gain ground as a quick and thorough way to check for surface discontinuities in ring gears, allow-ing the user to log a permanent record (map) for future reference. Phased array will gain wider acceptance as an improved method for inspecting sub-surface defects as acceptance criteria are established and validated in the large gearing industry,” Quinn says.

The technology is changing when it comes to inspecting large gears. Manufacturers of these components will be the first to tell you there are no short-cuts. Good news for those looking for the highest quality components for a massive application. For more information:Ferry CapitainPhone: +(33) 3 2594 [email protected] EngineeringPhone: +(61) 8 9279 5522Mail.hofmann@hofmannengineering.comwww.hofmannengineering.comRexnord CorporationPhone: (414) 643-3000www.rexnord.com

Photo courtesy of Ferry Capitain

Big or Small: Inspection is Key to SuccessWhile Hofmann, Rexnord and Ferry Capitain know big gears, compa-nies like Carl Zeiss, Wenzel and Klingelnberg know a little bit about inspecting them.

“Nowadays, large toothed gears are subjected to the same requirements as smaller toothed gears in station-ary transmissions or vehicle gearbox-es. Beyond the quality of the gearing, inspections must be conducted on the surface of the tooth flanks and the dimen-sions and measurements of the workpiece must be analyzed as a whole,” says Gunther Mikoleizig, product manager for precision measuring center, Klingelnberg GmbH.

“The actual inspection process for gears is quite simple,” says Todd Woijoviets, technical sales engineer at Zeiss Metrology. “The challenge comes when we look at gear standards. Manufacturers use different standards and different versions of the standard. This makes it difficult for everyone throughout the process because they must be up-to-date on all these standards and the changes between versions.”

Safety, of course, is always one of the key parameters for large gears. “A precision test of all parameters on large toothed gears provides a higher level of safety for the components,” says Mikoleizig. “An ongoing analysis of the results of the gear mea-surement can also provide helpful supplemental information, such as how to define or simulate the running conditions for the transmissions. This in turn produces shorter production and development times.”

At Wenzel GearTec, the company manufactures traditional, horizontal arm gear testers called WGTs, which are capable of measuring gears up to 3,000 mm in diam-eter (10 feet) and gantry-style vertical gear testers capable of measuring gears up to 4,000 mm (13 feet) in diameter. The vertical gantry-style machines called LHFGear also have the advantage of being able to measure large geometric, CMM parts, such as large bearing profiles and gearboxes on the same system and are also advanta-geous when measuring large internal gears.



feature SUPER-SIZED QUALITY CONTROL

“Portable gear testers can measure some gear features such as the pitch of adjacent teeth or lead and profile of individual teeth, but cannot accurately mea-sure diameters (reference diameters or dimensions over pins), planes, run-outs and other geometry,” says Andy Woodward, president, Wenzel America Ltd. “All Wenzel

gear measuring machines offer a full software suite for any gear type and also for gear cutting tools. Barkhausen Noise Analysis (for measuring stresses or damage due to grinding burn) and surface finish devices can be added to any Wenzel system.”

As a manufacturer of precision mea-suring centers, including for large and heavy workpieces of up to 4,000 mm outside diameter, Klingelnberg has been proactive in the development of equipment to test additional param-eters within a clamping. This includes opportunities for measuring surface roughness or undertaking grinding burn tests.

“Measurement of the dimensions, shape and position of the drive compo-nents can also be undertaken, to deliv-er comprehensive measurements of all parameters for a workpiece,” Mikoleizig says.

“Contact measurements are one of the best ways to inspect form and loca-tion of gear teeth. Plus with a Zeiss CMM, not only can you inspect the requirements of the gear but you can also inspect the housing of the gear, which is something that cannot be done with dedicated gear inspection equipment,” Woijoviets says. “The larg-est bridge type CMM Zeiss offers is a 2,000 mm × 4,200 mm × 1,500 mm. Then we move into a gant r y CMM. Our gantr y type CMMs have a measuring volume of up to 5,000 × 7,000 × 3,500.”

When Wenzel was presented the challenge of designing a CMM measur-ing solution for inspecting large ring gears and bearings for Liebherr Werk Bieberach GmbH, a German manufac-turer of large construction cranes, the company designed and built a special

CMM machine that combined their standard components and dual-arm measuring technology with the precision air bearing mechanics of the Wenzel WGT series of Gear Checkers.

“The inspection machine is capable of inspecting bearings and ring gears up to 6,000 mm (19.68 ft) diameter. The dual-arm machine design is similar to what Wenzel has applied in the automotive industry to measure car bodies and body components,” Woodward says.


Photo courtesy of Wenzel


In this design, the CMM measuring arms are each mounted to a table that is mounted on a large corresponding granite base. The measuring arms feature high accuracy linear guideways for the X-axis. The Y- and Z-axes feature finely tuned preloaded roller bearings providing minimum friction and operational wear. The base units are positioned opposite each other with a rotary fixture table in between. Both arms measure the large rings concurrently, and the metrology of each measur-ing arm is harmonized through the use of a specially designed calibration tool.

“The ring gears and bearings are located and clamped on the 2,200 mm (7.21 ft) diameter hydrostatic rota-ry table that can handle loads up to 100,000 lbs. The complete circum-ferences of the rings are inspected by a single inspection part program. Application software is also provided that can calculate the optimum fitting tolerance for inner and outer bearing components.”

So what’s the moral of the story? Manufacturers of large and small gears can get technology that will make gear inspection easier and more user-friend-ly no matter the size requirements. For more information:Carl Zeiss Industrial MetrologyPhone: (800) [email protected]/metrologyKlingelnberg GmbHPhone: (734) [email protected] AmericaPhone: (248) [email protected]

Photo courtesy of Carl Zeiss

Photo courtesy of Wenzel


Response provided by Octave LaBath.In September 2005, I produced a spreadsheet comparing four references for crowning on parallel shaft gearing. I have since added a fifth reference:

References on Crowning:1. McVittie, Don. “Our Experts Discuss Hobbing Ridges,

Crooked Gear Teeth and Crown Shaving,” Gear Technology, March/April 1992, pp. 41-43.

2. Stokes, Alec. High Performance Gear Design, Machinery Publishing, 1970, p. 89.

3. Merrit, Henry Edward. Gear Engineering, John Wiley & Sons, 1972, p. 124.

4. Dudley, Darle, Ed. Gear Handbook, McGraw Hill, 1962, p. 5-24.

5. National Broach & Machine Division. Modern Methods of Gear Manufacture, Lear Siegler, Inc., p. 77.

Example 1 (McVittie)“The amount of crown is critical,” McVittie says, “since too much total crown in the pair of gears will concentrate the con-tact into a narrow area of the face and lead to premature pitting failures. A reasonable rule of thumb is ‘no more than .0003 to .0005 inch’ of crown per inch of face.”Face 2.000" (50.8 mm)Crown Minimum = Face • 0.0003 = 0.0006" (0.015 mm) Maximum = Face • 0.0005 = 0.001" (0.025 mm)

Therefore the tooth thickness of a 2.0" face width gear would be 0.0012" to 0.0020" less than in the center of the face width.

Example 2 (Stokes)“For any power gearing application,” Stokes says, “it is essential that perfect tooth contact is obtained. To allow for any misalignment in the mountings of the gears, or heat treatment distortion, it is usual to crown the tooth form, i.e., produce elliptoid teeth, thus eliminating any chance of end loading the gear tooth.”

According to Stokes, crowning is usually .0002 to .0003 inches crowning per inch of face width, with a maximum of .0005 inches per inch of face width.Face 2.000" (50.8 mm)Crown Minimum = Face • 0.0002 = 0.0004" (0.010 mm) Maximum = Face • 0.0005 = 0.0006" (0.015 mm)

Example 3 (Merritt)“Symmetrical crowning is applied in order to avoid hard bearing at tooth-ends, which might other-wise occur as a result of errors of tooth alignment,” says Merritt. According to Merrit, crowning can be

based on the gear’s pitch, with crowning per flank commonly around .005/P to .01/P.

Assuming a square pinion, the pitch diameter would be 2.000 inches.Pitch 10 NDP (2.54 module), 20 teethCrown Minimum = 0.005/NDP = 0.0005" (0.0127 mm) Maximum = 0.01/NDP = 0.0010" (0.0254 mm)

Pitch 20 NDP (1.27 module), 40 teethCrown Minimum = 0.005/NDP = 0.0003" (0.0064mm) Maximum = 0.01/NDP = 0.0005" (0.0127 mm)

Example 4 (Dudley)“In effect, crowning allows a rocking-chair-like action between the teeth when the shafts deflect into increasingly nonparallel positions,” Dudley says. “Heavy concentrations of load at the ends of the teeth are avoided.” Dudley suggests that the ends of crowned gears are made .0005 to .0020" thinner at the ends as compared to the middle.Crown Minimum = 0.00025" (0.0635 mm) Maximum = 0.0010" (0.0254 mm)

Example 5 (National Broach)According to this handbook, “Excessive crowning is as great an evil as no crowning. When the amount of crown is too great, effective face width is sacrificed…If the accumulated mounting errors or shaft deflection appear to call for gear tooth crowning in excess of 0.0005-in. per inch of face width on each tooth side, more rigid mounts, or stronger gear teeth should be considered.”Face 2.000" (50.8 mm)Crown Maximum = Face • 0.0005 = 0.0010" (0.0254 mm)

Crowning Spur Teeth

When designing spur teeth, is there a formula/guideline/design guide for determining the amount of crowning?

QUESTION #1

Crown Magnitude


ask the expert

DiscussionI prefer the methods that have the amount of crown as a function of the face width. This eliminates References 3 and 4.

The method given in Reference 2 seems to give too small an amount of crown.

The Reference 1 method is similar to the method given in Reference 5, but has a tolerance range. There should be a toler-ance on the amount of crown, so I like the method given in Reference 1 best. This ref-erence actually mentions Reference 5.

Octave LaBath enjoyed a 30-plus year career at Cincinnati Gear. A Gear Technology technical editor and longtime AGMA member and contributor of his time and expertise to the association, he now heads up a consultancy — Gear Consulting Services of Cincinnati, LLC — and can be contacted at [email protected].

Power Transmission Engineering “Expert”/Technical Editor Octave LaBath with his gear apprentice Max, who also happens to be his grandson.

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Do YOU have a gear-related technical question?Get an answer by submitting it to our expert panel!Submit you question to Jack McGuinn, Senior Editor,

via e-mail at [email protected]

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What gear material is suitable for high-temperature (350 – 550°C), high-vacuum (10 –8 torr), clean-environment use?

QUESTION #2

High-Temperature Gear Materials

Email your question—along with your name, job title and company name (if you wish to remain anonymous, no problem) to: [email protected]; or submit your question by visiting geartechnology.com.

Expert response provided by Dr. Philip Terry:

From time to time, general questions arise concerning the maximum tempera-ture at which gear materials can oper-ate — or specific questions about what material is suitable for a specific — usu-ally elevated — temperature. When faced with these questions, gear metallurgists and material technologists usually look at the limits imposed by virtue of the previous thermal processing of the gear materials. Gears are rated (that is, the ability of the gear teeth to carry Hertzian contact stresses and bending loads) as a function of the hardness of the material and, in particular, the surface hardness of the tooth.

The hardness of gear steels is typi-cally achieved by through-hardening (quenching and tempering), nitriding or carburizing.

In the production of through-hardened gears, the part is taken to a high tempera-ture to austenitize the material, and then quenched in oil, water or other cooling medium to produce a hard, martensit-ic, metallurgical structure finally tem-pered to impart toughness and ductility. The tempering temperature is typically in the range 900 to 1,150°F. Following this final temper, any exposure to tempera-tures at or close to the selected tempering temperature will reduce the hardness of the material and, consequently, lower the load-carrying capability of the material when used for gearing.

Nitriding is also typically performed in the region of 900°F, and so material

intended to be nitrided is normally tem-pered at around 950°F to avoid over-tempering during the nitriding process. Nitrided gears are, therefore, constrained to running temperatures below 900°F to prevent softening in service.

The highest hardness material used in industrial gears and therefore the gears with the greatest load carrying capabil-ity are those which are surface hardened by carburizing. However the final tem-pering temperature used on carburized gears immediately prior to finishing is in the region of 375°F, and although carbu-rized gears have the highest known load capacity, this low tempering temperature restricts the temperature at which they can be used to around 300°F.

Below is a summary table based on ensuring that gear hardness does not drop as a result of exposure to high tem-perature in service based on a maximum temperature 50°F below the final tem-perature used on the material during thermal processing.

Temperature limits for gear materialsProcess Temperature Limit °F

Through-hardened 850Nitrided 850

Carburized 300

The values shown in the table are typ-ical levels; if details of a specific heat treatment cycle are known, and higher final temperatures are used, the limits can be raised to within 50°F of the actual temperature. Similarly, if a specific ser-vice temperature needs to be accom-

modated, lower limits can be imposed on the tempering temperature to ensure that parts will not soften due to over-tempering in service.

The temperatures quoted here are for the commercial alloys most frequently used for gear manufacture; other more specialized alloys exist which have been specifically designed for higher tempera-ture applications such as the Pyrowear family of alloys for carburized parts. Some of these alloys are tempered after carburizing at 550°F, thus extending their range of application up to 500°F.

The comments in this article refer to the temperature limits of the steel base material of gears, and do not discuss the issue of temperature limitations for gear lubricants, which need to be evaluated separately.

Dr. Philip Terry was born and educated in the U.K., receiving in 1972 his doctorate in materials science/fracture mechanics. He has decades of metallurgy-and-materials experience in various design and managerial capacities at companies such as British Steel Corp., Cameron Iron Works, and, for 15 years until his retirement in 2011 — Lufkin Industries. Terry has also been an invaluable AGMA member over the years, having served on or chaired many of its materials- or heat treat-related committees. He currently serves as the standing U.S. representative on ISO TC 60 WG 14 – Metallurgy. Terry is now un-retired, working as an independent consultant specializing in material selection, heat treatment, welding-and-fabrication, and failure analysis ([email protected]).


ask the expert

Expert response provided by Rob Frazer, senior engineer at the Design Unit:

The position that you find yourself in is very common. Gear technology is not a particularly difficult subject to under-stand, but it covers many fields of expertise and thus there are many elements that need to be appreciated and under-stood before a full specification can be prepared that will ensure that you get gears that are fit for purpose and meet your needs.

To put it bluntly, if we don’t specify gears properly we get the gears we deserve rather than the ones we actually need.

This is a challenging task for people who do not regularly specify gears. Because we have no knowledge of your spe-cific application for fine-pitch gears, the following guidance is generic for most gears and we will assume that specifying the geometry itself is sufficient and that the life and loading is evaluated separately.

Gear standards, whether they are published by AGMA or ISO, are a very valuable source of reference material for gear designers. However these are written for people who have the relevant background gear knowledge and expertise to imple-ment the procedures and, more importantly, interpret the results from applying the standard procedures. The AGMA information sheets and ISO Technical Reports are prepared by the expert working groups to provide guidance on imple-menting and understanding them. It is also of course impor-tant to ensure you are referring to the latest version of the standard. This is not helped by the fact that within AGMA and ISO publications, none fully address the specification requirements of gears.

But before you try and specify gears starting with a blank sheet of paper, there are other options that should be explored first that, although apparently more costly, may save much of your time and potentially avoid costly mistakes:

Employ a consultant to specify the gears for you. The bene-fits from this are that you will get a full specification that will provide you with the gears you need. The disadvantage is that you won’t learn anything yourself and if you need to modify the design or experience quality problems, you will have to re-employ your consultant.

Alternatively, you can seek a reputable gear supplier who is willing to provide the design and manufacturing expertise to supply gears that will meet your needs. You would need to specify life and duty cycle (load and speed) requirements; the drive element (e. g., electric motor specification); the load characteristic; size envelope; gear shaft and gear housing tol-erances; manufacturing methods; environmental conditions (temperature and humidity); preferred materials; operating backlash; noise requirements; and annual quantities. Again, if you want to modify anything, you rely on the supplier for these design changes.

The application in this example is not defined, but the 0.8 mm module gears could potentially be supplied by a cat-alog gear supplier who specialize in small-pitch, standard geometry gears; your question implies that you have already considered this. A number of catalog gear companies offer a range of gears that may be suitable for your requirements. They can supply small quantities of gears but may also be suitable for larger volume manufacture and also provide

So What’s to Know About Specifying a Gear?

Only Everything!

I am trying to specify a few .8 module metric gears and am being asked to include as many gear specifications as possible on our drawings.For example, one of the gears we need is a .8 module 40t gear, so my plan was to say this:Spur Gear: Teeth = 40, Module = .8, PD = 32, Circ Tooth Thickness = 1.17 (using this to determine backlash, but there is probably a better way)For all other tolerances and design information, reference AGMA 2000-A88, Q8 (we found some stock gears that listed this number but don’t really know what it means). I see so many different AGMA and ISO standards for gears and I’m just not sure which one I need. We haven’t purchased any yet and don’t want to until we know which one to use. Can you shed some light on this or point me in the right direction? I don’t know why but this seems like a real mystery to us!Thank you!

QUESTION #3


ask the expert

guidance on suitable geometry tolerances, tooth thickness tolerances to ensure the gears operate with acceptable backlash. Using off-the-shelf or modified catalog gears often provides the cost-effective solution to prototype or small volume gear applications.

There are many commercial software programs available that can assist you to design, analyze and specify gear geometry. These range considerably in terms of complexity and cost, but the best allow users to invoke ISO and AGMA accuracy stan-dards, use standard proportion cutting tools, define and evaluate tooth thickness (for backlash calcula-tions) and evaluate the gear pair using stress anal-ysis standards such as AGMA 2101 or ISO 6336. Many programs provide graphics that enable the users to properly visualize the gear pair they are specifying. The most basic of these programs is a simple automated gear calculator, while the most sophisticated programs provide help and guid-ance when things are starting to go wrong (Fig. 1). But users need to understand what the programs are doing and thus it is recommended that proper training is obtained prior to use. Few people are provided with sufficient training in gear technol-ogy in college and university courses, but help and guidance is provided by the AGMA in their training program (www.agma.org). In the U.K. the British Gear Association (BGA) has an extensive seminar program that allows those new to the gear industry to attend a series of short courses to intro-duce them to gear technology (www.bga.org.uk).

The strategy adopted by the Design Unit (at Newcastle University, U.K.) for specifying gears is that you provide unambiguous data relating to the geometry of the finished gear. Our policy is not to specify the details of the manufacturing procedure and thus a full gear specification comprises seven elements:1. The nominal basic macro gear geometry (module, tooth

number, helix angle, tip diameter, root diameter, face width, addendum modification coefficient). ISO 21771 provides formula for these parameters.

2. The specification of microgeometry corrections to the tooth flank (tip relief, helix crowning) on gears that are transmitting significant amounts of power or have strin-gent noise and vibration requirements.

3. Cutting tool geometry data (depth, pressure angle, cutting tool tip radius used to cut the tooth root region, grinding allowance or backlash allowance). AGMA 1003 and 1006 provide information of the proportions of tooth for fine-pitch gears and plastic gears.

4. Tooth thickness data specifying the tooth thickness toler-ances to ensure operating backlash is achieved when the gear is manufactured and assembled. We normally define gear circular tooth thickness indirectly because measuring a circular arc length is difficult. We use parameters such as dimension-over-pins or span size over several teeth. Refer to ISO 21771 for tooth thickness calculations. AGMA 2002 provides guidance on tooth thickness tolerances. There is

no ISO standard directly related to tooth thickness allow-ance and backlash.

5. A gear geometry accuracy specification is defined by ISO or AGMA tolerance classification standards. Two methods are commonly used here:a. The measurement of individual errors (profile, helix or

tooth alignment, pitch errors, radial runout of the tooth space and tooth thickness). AGMA 2015-1 (replaced AGMA 2000) specifies allowable limits for different tol-erance classes and is similar to ISO1328-1. Note that these do not provide guidance on which tolerance grade to pick. For most applications, precision-cut gears of grade 7 or better (lower grade number) are achievable, with molded, fine-pitch gears of grade 9 to grade 10 commonly specified. The tolerances that are specified must consider power transmission, noise and tolerance build-up of the assembled gear assembly. The accuracy of the gear is verified by measurement with CMMs or dedicated gear measuring machines and fine-pitch gears of 0.4 mm module can be easily measured (Fig. 2). The process provides feedback to show that the gears comply with the accuracy specification and also identify what has gone wrong with the manufacturing process.

Figure 1 Example of a software package used to develop a gear specification with built in warnings when you approach normal geometry limits (courtesy Dontyne Systems Ltd).


b.

The second method is the measurement of radial com-posite errors or dual-flank errors, and is commonly used to control fine-pitch gear tolerances. The method involves meshing a product gear with a precision-ground mas-ter gear (a minimum of 3 accuracy grades better than the product gear) under light load with zero backlash, and recording the change in center distance as the gears rotate. AGMA 2015-2 and ISO 1328-2 both provide allow-able tolerances for gears of 0.8 mm mod-ule, and the quality grades mentioned above equally apply to this measurement method. This also provides a method of measuring tooth thickness by specifying upper and lower indicator limits based on maximum and minimum center distance values.

6. Material specification, including material type and where appropriate the range of acceptable hardness values and case depth requirements.

7. The datum axis that is used to define the gear geometry and provide a functional location for the gears when in service.A typical realization of a gear specifica-

tion is illustrated in Figure 4 for ISO 1328-1 grade 9 gears, assuming quality is controlled by helix, profile, pitch tolerances and tooth thickness, defined by dimension over balls or pins. An alternative specification using ISO 3128-2 for dual-flank testing measurement strategy is illustrated in Figure 5.

In conclusion, the specification of gears requires a detailed knowledge of gear geome-try, manufacturing methods, inspection meth-ods, material and the functional requirements of the application. Every gear designer has his or her own preferred method, but asking the right questions, using the appropriate stan-dards and support software ensures it is pos-sible to specify gears reliably.

Dr. Rob Frazer is a senior engineer at the Design Unit, the Gear Technology Centre at Newcastle University in the U.K. Frazer is head of the U.K.’s National Gear Metrology Laboratory and is responsible for gear design and gear analysis within the Unit. He also serves as chair of BSI MCE-5, the U.K. committee responsible for over 90 gear-related standards and is the U.K. representative on the ISO Gear Accuracy Committee (ISO TC60 WG2). Frazer is actively involved in delivering the British Gear Association’s training seminar program in the U.K.

Figure 2 Klingelnberg P65 with a 0.5 mm diameter probe Inspecting a 0.7 mm module gear in accordance with ISO1328-1 (the minimum standard probe is 0.3 mm diameter).

Figure 3 Frenco-dual flank roll tester for measuring composite Radial deviations in accordance with ISO1328-2.

Figure 5 Example gear specification for ISO 1328-2 accuracy gears.

GEARDATABasic Geometry

Number of teeth 40Normal module 0.800Reference pressure angle 20.000Ref.helix angle (left) 0.000Addendum Mod. coefficient 0.0000Nominal tooth depth/Mn 2.400

Reference DataFacewidth 5.000Tip Diameter 33.600Root Diameter 29.760

ToppingBase helix angle 0.000Reference Diameter 32.000Base Diameter 30.070

Finished Tooth ThicknessBall Diameter 1.440Dimension over balls (nom) 34.022Dimension over balls (max) 34.022Dimension over balls (min) 33.943

Flank TolerancesReference axis datum bore AAccuracy Standard ISO 1328-2/97Grade 9Single composite tol 11 µmTotal composite tol 56 µmTool tip radius 0.312

Meshing InformationMating gear

Centre distance nominal 32.000Start of active profile dia 30.851Contact ratio 1.714Normal backlash max 0.160Normal backlash min 0.100

Material & Heat TreatmentThrough Hardened (V)

Surface hardness 200 HvAngles are in ° and distances in mm unless

otherwise stated

GEARDATABasic Geometry

Number of teeth 40Normal module 0.800Reference pressure angle 20.000Ref.helix angle (left) 0.000Addendum Mod. coefficient 0.0000Nominal tooth depth/Mn 2.400

Reference DataFacewidth 5.000Tip Diameter 33.600Root Diameter 29.760

ToppingBase helix angle 0.000Reference Diameter 32.000Base Diameter 30.070

Finished Tooth ThicknessBall Diameter 1.440Dimension over balls (nom) 34.022Dimension over balls (max) 34.022Dimension over balls (min) 33.943

Flank TolerancesReference axis datum bore

AAccuracy Standard ISO 1328-1/95Grade 9Adjacent pitch tol 20 µmCumulative pitch tol 57 µmProfile tol 21 µmHelix tol 25 µmTool tip radius 0.312

Meshing InformationMating gear

Centre distance nominal 32.000Start of active profile dia 30.851Contact ratio 1.714Normal backlash max 0.160Normal backlash min 0.100

Material & Heat TreatmentThrough Hardened (V)

Surface hardness 200 HvAngles are in ° and distances in mm unless

otherwise stated

Figure 4 Example gear specification for ISO 1328-1 accuracy gears.


ask the expert

technical

Design and Optimization of Planetary Gears Considering All Relevant InfluencesTobias Schulze

Gear Design ProcessLight-weight construction and consideration of available resources result in gearbox designs with high load capacity and power density. At the same time, expectations for gear reliability are high. Additionally, there is a diversity of planetary gears for different applications. Gears with one or more stages and with one or more gearbox inputs and outputs are not uncommon. Furthermore, different kinds of teeth exist: e.g., spur and helical gears, and also double-helical gears are doable. For the mount-ing of shafts and gearings, roller bearings and sliding bearing are used (Fig. 1).

All of these conditions require exceptional and robust design criteria, including maximum load and dynamic loads under dif-ferent load situations. Experience with drivetrains with stiff foun-dations and constant, external loads is not directly applicable, due to unique boundary conditions, dynamic excitation of the struc-ture, and changing influences by external conditions (Ref. 12).

The product design process of a gear typically begins with the load calculation, followed by gear and component layout, to the point of structure analysis (Fig. 2).

Only at a test bench, or in industrial use as a component in the whole drivetrain, can the quasi-static and dynamic behavior of the gear in actual conditions be verified. This long chain in the process does not allow for an efficient gear cal-

culation — especially considering the insecurities of the load assumptions — and with that the inevitable, inaccurate stress of the single machine elements and resulting strains.

In these cases the highly precise and, in part, standardized calculations of machine elements can only be applicable as far as the accuracy of the load assumptions allow. Any interactions of the single elements within the stressed gear (e.g., the influ-ence of axle bending on the load dispersion of the gearing) are thereby lost. Furthermore, the gear must —especially with flex-ible shafts, housing or dynamic excitation — be understood as a sub-system of the drivetrain; only in this way can a realistic load gradient be constructed (Ref. 13).

An evenly balanced calculation model for drivetrains that connects all concerned sub-disciplines (external conditions, drivetrain dynamics, structure dynamics, electrical phenomena and machine regulation) in a comparative model depth does not exist (Fig. 3). And yet, only such a balanced model allow-ing for all needed conditions can deliver the realistic and reli-able statements on dynamic strains needed to make the safe design of drive components possible (Ref. 15).

The resulting problems and damages cannot be fully explained through mere analysis of the single modules. In fact, the essen-tial influences of the surrounding system components must be accounted for and included in the computation. Here arises the

Figure 1 Application of planetary gears (Ref. 13).

Figure 2 Classic product design process.

96 GEAR TECHNOLOGY | November/December 2013[www.geartechnology.com]

technical


real difficulty of finding the necessary system parameters to solve the respective question, which is why the product develop-ment process of the future is moving more and more to system analysis, rather than the design of single machine elements. Vital to gear development is continuous — mostly software-support-ed — analysis, result-conditioning and data maintenance to the point of supervision of the lifecycle of a gear. On one side, all calculations of the machine elements — gear, axle, bearing, axle-hub connection, screw connection, etc. — are to be implemented following the current standards. These must be supplemented through detailed examination of load gradients and load distri-bution — and to the point of optimization of single target param-eters (mass, stiffness).

Gearbox Development and Calculation According to StandardsEspecially for design concepts of planetary and spur gear-boxes, the newest software development of DriveConcepts GmbH — MDESIGNgearbox — is established. This calculation software gives complete product information in the early phase of the product lifecycle (PLC). The calculation cannot replace measurements and test drives, but iteration steps can be reduced economically. The software allows for an intuitive and easy han-dling in the design process of the entire gearbox — dimensioning

of the machine elements (shafts, bearings and toothings) — all according to the existing standards (Refs. 5–7).For toothing:• DIN 3990:1987 T1–T6• ISO 6336:2008 T1–T3, T5 and Technical Corrigendum 1:2008Future work for toothings:• Micropitting according to ISO/TR 15144–1• Scuffing according to ISO/TR 13989 1 and 2, AGMA 925• Gear mesh efficiency/loss factor HV and HVL

The shafts of the gearbox are calculated according to:• DIN 743:2008 T1–T4 and Beiblatt 1, 2• Different calculations possible for the roller bearings:• Lifetime LH10 according to DIN ISO 281:2009• Modified lifetime according to DIN ISO 281:2009, Beiblatt 1, 3• Advanced modified lifetime according to DIN ISO 281:2009,

Beiblatt 1, 3• Lifetime according to ISO/TR 16281:2009

The software enables calculation of the system gearbox in one step, including a complete documentation into a PDF/A docu-ment, according to ISO 19005–1:2005 (Fig. 4).

Gear Optimization (Macrogeometry)The following shows the gear optimization in some case studies:

Load distribution. Next to the load distribution factor KHβ

one of the important tasks of gear development is to optimize

Figure 3 Design process of a gear as a system.

Figure 4 User interface of MDESIGN gearbox with 3-D-GearDesigner and result page (Ref. 10).

97November/December 2013 | GEAR TECHNOLOGY 37VOLUME 3, ISSUE 1 GEAR TECHNOLOGY INDIA

technical

the load distribution of each planet gear. This is done using a pure statistic model that determines load distribution factor K. The load distribution factor is defined as “the ratio of the maximum tooth normal force to the median tooth normal force at the speed of zero.” Dynamic factors are represented by the factor Kv. The median con-tact stiffness from the load gradient calculation is used for the analysis, as well as wheel body stiff-ness (sun, ring gear), bearing stiffness and bear-ing clearances (sun, planet, ring gear and planet carrier). The following deviations can be accom-modated (Fig. 5):• Single-pitch deviation — sun and ring gear• Tooth width variations — planet gear• Center distance deviation and planet carrier

pitch deviations• Displacement — sun, planet carrier, ring gear

The computation of the load distribution allows statements on suitable tolerances or tolerable location variations with exact knowledge of the real load for every single planet. These inves-tigations allow, for example, single parameters to be analyzed with regard to their influence on the load-bearing capacity of the gearing (Fig. 6).

Suitable construction parameters, as well as sensible toler-ances of gearings and location variations, can be defined. Research on load distribu-tion (Kγ and KHβ) has shown that only a simultaneous optimization of load distribu-tion on flank (KHβ) and plan-ets (Kγ) results in an opti-mal gear (Fig. 7). An effec-tive instrument for a balanced load distribution is the use of optimized, flexible plan-et gear bearings. The impact is due to the targeted over-lapping of bolt and bush-ing bending, with the goal of minimizing the tilt angle of

the planet, which in turn is determined by the deforma-tion of the bushing (Ref. 16).

Stiffness optimization. The optimization of construc-tion parameters with the goal of optimal stiffness of all relevant gear elements is probably one of the most com-plex development tasks in the design process. Typical is the description of the following variation analysis of a planet mount: “the goal is a design with the least pos-sible mass while retaining necessary stiffness require-ments needed in view of the load gradient (Fig. 12).” Both one-sided and two-sided samples can be consid-ered; they can be constructed with a round or optimized outline (triangular, square) (Fig.8).

The geometric parameters to be varied in such a study are shown (Fig. 9). Through the large amount of parameters it is necessary to use software programs

Figure 5 Computation model for load distribution KHβ.

Figure 6 Variation studies for load distribution KHβ

Figure 7 Variation studies for load distribution KHβ and KHβ.


technical


Figure 8 Variants of planet carriers: single-plate (left); double-plate (right) (Ref. 3).

Figure 9 Geometric parameters of planet carriers: single-plate (left); double-plate (right).

Figure 10 Optimization mass and design space.

with integrated FE solvers for calculating stiffness parameters; only in this way can optimal configurations be found for the entire parameter area.

Mass/design space optimization. Not only has the just-intro-duced stiffness optimization led the engineer to a number of detail problems; the search for a mass, construction-size opti-mized gear is a highly complex question due to the number of overlapping influences. Figure 10 shows the field of results of a variation study for a constant, given total gear ratio and defined load.

The investigation can be used for improving present gear solutions, as well as for new designs. Using an existing design as an example, the following shows how great the potential can be (Fig. 11).

At similar dimensions for the ring gear outer diameter d3 of gear Stage 2, one arrives at a mass savings by adjusting the ring gear diameter for Stage 1 and reducing the tooth width.

MDESIGNgearbox avoids the over-dimensioning of planet gears by pre-setting safety factors for the gearbox machine elements. The mass of the original is at mges ≈ 2,200 kg. All generated, optimized solutions arrive at a mass reduction in comparison to the actual gear. The mass, optimized preferred variation is shown (Fig. 12, right).

In this example the mass savings amount to about 25 percent, in respect to the original design. At the same time the optimiza-tion of the construction space amounts to 15 percent (Fig. 3). In a second step the consideration of CAD geometry data of hous-ings will be possible. Therefore the software imports a standard geometry format, generates finite element models, calculates stiff-ness matrices for the housing, and delivers this information to the design process of MDESIGgearbox (Fig. 14).

Optimization of microgeometry. The calculation of load dis-tribution in a planetary gear system essentially depends on the helix angle deviation between the contact flanks of the gear


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Figure 11 Variation study mass optimization: initial state (left); mass optimized gear (right).

Figure 12 Variation study design space: Initial state (left); space-optimized gear (right).

Figure 13 Savings potential: mass (left); design space (right).

Figure 14 Determining of stiffness matrices in 3-D-HousingDesigner.


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pairs; it can be understood as the sum of different influ-ences. It is assumed that the effects are overlying inde-pendently, thus the sum of contact line deviation can be calculated with the single deviations (Ref. 11).

The calculation of single displacements and deforma-tions of all gearbox bodies — especially the planet car-rier, the coupling of ring gear and gear wheel bodies and the deformation of teeth — is more complex in plan-etary gearboxes than in spur gearboxes. To determine the load distribution, the flank deviation for the tooth contact sun/planet and the tooth contact planet/ring gear is calculated by the new software MDESIGNLVRplanet

(Refs. 8 and 9). The result of the calculation is the exces-sive line load, which is expressed by the factor KHβ. In general, the excessive line load is on the flank side opposite the deviated flank side.

Next to the calculation of the ratio of maximum and middle line load, the software gives detailed information about tooth flank pressure and tooth root stress distribution (Fig. 15).

The flank deviation (FLKM) consists of the following parts:• Elastic deformation of gear body (veRK)• Elastic tilting difference of roller bearings /17/ (veWL)• Torsion deformation of planet carrier (vePT)• Tilting of planet due to of sliding bearing (verkippPL)• Effective helix angle modification (fHβeff)• Elastic deformation of tooth flank• Elastic deformation difference of planet carrier bearing• Deformation of housing

The helix angle deviation for tooth contact sun/planet is cal-culated by the following equation:

(1)FLKM½ = ve1 + ve2172 + veWL½ + vePT½ verkippPL½ + fHßeff½

The helix angle deviation for tooth contact planet/ring gear is calculated by the following equation:

(2)FLKM⅔ = ve1 + ve2⅔ + veWL⅔ + vePT⅔ verkippPL⅔ + fHßeff⅔

ve1 = deformation difference of sun ve2 = deformation difference of planet ve3 = deformation difference of ring gear

The deformation is calculated by FE method and is then added to the flank deviation. All parts of the helix angle devi-ation have to be added as values normal to the flank. The database of the calculation is saved in XML format. With this, a structured depositing of design, modification, deviation, load and control data is possible. Furthermore, the program has a project management capability for saving projects, standard examples and more calculation guidelines (Ref. 14).

After input of all necessary parameters: all data are checked, the design models are generated and the FE models for the gears with coupling design and the planet carrier are created. For an efficient calculation it is necessary and reasonable to use drive technology software. DriveConcepts GmbH develops software solutions for drive technology, which is characterized by clear and intuitive handling of all data. In the background, academic-established calculation kernels and consistent, struc-tured interfaces help solve the actual task efficiently.

Case StudyThe example of a wind turbine with 2,000 kW output power should show the consequences of different flank modifications with constant load (Ref. 12). The main gearbox consists of one planetary gear stage and two spur gear stages (helical gearing). The detailed parameters of the first planetary gear stage are listed (Fig. 16). The initial state of unmodified gearing under

Figure 15 Verification of planetary gear stages.

module m 16 mm face width b1|2|3 310 mmnumber of teeth z1|2|3 20 | 36 | -91 add. modification sun x1 0.4

center of distance a 463 mm add. modification planet x2 0.3156pressure angle α 20° add. modification ring gear x3 -1,6429

helix angle β 8°

Figure 16 Application case.

101November/December 2013 | GEAR TECHNOLOGY40 GEAR TECHNOLOGY INDIA VOLUME 3, ISSUE 1 [www.GearTechnologyIndia.com]

pairs; it can be understood as the sum of different influ-ences. It is assumed that the effects are overlying inde-pendently, thus the sum of contact line deviation can be calculated with the single deviations (Ref. 11).

The calculation of single displacements and deforma-tions of all gearbox bodies — especially the planet car-rier, the coupling of ring gear and gear wheel bodies and the deformation of teeth — is more complex in plan-etary gearboxes than in spur gearboxes. To determine the load distribution, the flank deviation for the tooth contact sun/planet and the tooth contact planet/ring gear is calculated by the new software MDESIGNLVRplanet

(Refs. 8 and 9). The result of the calculation is the exces-sive line load, which is expressed by the factor KHβ. In general, the excessive line load is on the flank side opposite the deviated flank side.

Next to the calculation of the ratio of maximum and middle line load, the software gives detailed information about tooth flank pressure and tooth root stress distribution (Fig. 15).

The flank deviation (FLKM) consists of the following parts:• Elastic deformation of gear body (veRK)• Elastic tilting difference of roller bearings /17/ (veWL)• Torsion deformation of planet carrier (vePT)• Tilting of planet due to of sliding bearing (verkippPL)• Effective helix angle modification (fHβeff)• Elastic deformation of tooth flank• Elastic deformation difference of planet carrier bearing• Deformation of housing

The helix angle deviation for tooth contact sun/planet is cal-culated by the following equation:

(1)FLKM½ = ve1 + ve2172 + veWL½ + vePT½ verkippPL½ + fHßeff½

The helix angle deviation for tooth contact planet/ring gear is calculated by the following equation:

(2)FLKM⅔ = ve1 + ve2⅔ + veWL⅔ + vePT⅔ verkippPL⅔ + fHßeff⅔

ve1 = deformation difference of sun ve2 = deformation difference of planet ve3 = deformation difference of ring gear

The deformation is calculated by FE method and is then added to the flank deviation. All parts of the helix angle devi-ation have to be added as values normal to the flank. The database of the calculation is saved in XML format. With this, a structured depositing of design, modification, deviation, load and control data is possible. Furthermore, the program has a project management capability for saving projects, standard examples and more calculation guidelines (Ref. 14).

After input of all necessary parameters: all data are checked, the design models are generated and the FE models for the gears with coupling design and the planet carrier are created. For an efficient calculation it is necessary and reasonable to use drive technology software. DriveConcepts GmbH develops software solutions for drive technology, which is characterized by clear and intuitive handling of all data. In the background, academic-established calculation kernels and consistent, struc-tured interfaces help solve the actual task efficiently.

Case StudyThe example of a wind turbine with 2,000 kW output power should show the consequences of different flank modifications with constant load (Ref. 12). The main gearbox consists of one planetary gear stage and two spur gear stages (helical gearing). The detailed parameters of the first planetary gear stage are listed (Fig. 16). The initial state of unmodified gearing under

Figure 15 Verification of planetary gear stages.

module m 16 mm face width b1|2|3 310 mmnumber of teeth z1|2|3 20 | 36 | -91 add. modification sun x1 0.4

center of distance a 463 mm add. modification planet x2 0.3156pressure angle α 20° add. modification ring gear x3 -1,6429

helix angle β 8°

Figure 16 Application case.


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nominal load is shown (Fig. 17, left side). In this case the ratio of maximum and mean value of line load is 1.67.

In the first step of optimization with a helix flank modifica-tion, the factor can be reduced to KHβ = 1.23 (Fig. 17).

The rest of t h e unbalanced distribution along the face width — which comes from planet carrier torsion deforma-tion — can be offset with an optimal lead crowning. The ratio of maximum and middle-line load can be reduced to KHβ = 1.16 (Fig. 18, left).

At t h e right side of Figure 18 i t is shown that an over-sized lead crowning can also lead to poor conditions. In this case the lead load distribution changes to KHβ = 1.98. The exam-ple shows the necess ity of the right dimension of macroge-ometry and also of used modifications. If these are correct, the lead load distribution KHβ can be reduced from 1.67 to 1.16; but with unfavorable modifications, the opposite will be the result.

This case study shows advantages of MDESIGN 2010 with the libraries LVR, LVRplanet and gearbox to develop gearboxes in a very efficiency way.

References1. Börner, J. and M. Senf. “Verzahnungsbeanspruchung im

Eingriffsfeld — Effektiv Berechnet,” Antriebstechnik 1, 1995.2. Börner, J. “Very Efficient Calculation of the Load Distribution on External

Gearsets — Method and Application of the Program LVR,” International ASME Conference, San Diego, 1996.

3. Hartmann-Gerlach, Christian. “Verformungsanalyse von Planetenträgern unter Verwendung der Finiten Elemente Methode,” Internal Draft, TU, Dresden 2008.

4. Hohrein, A. and M. Senf. “Untersuchungen zur Last und Spannungsverteilung an Schrägverzahnten Stirnrädern,” Ph.D. Thesis, TU, Dresden 1978.

5. ISO 6336. 2006 Calculation of Load Capacity of Spur and Helical Gears.6. Linke, H. Stirnradverzahnung — Berechnung, Werkstoffe, Fertigung,

München, Wien: Hanser, 1996.

7. Linke, H. Beitrag zur Ermittlung der Zahnflanken und Zahnfußtragfähigkeit unter Berücksichtigung der Abweichungen geometrischer Größen, Deformation der Getriebeteile und der Werkstoffkennwerte, Habilitationsschrift, TU, Dresden 1978.

8. MDESIGN LVR 2010. Software for Load Distribution of Multi-Stage Spur

and Helical Gears, DriveConcepts GmbH, 2010.9. MDESIGN LVRplanet 2010. Software for Load Distribution of Planetary Gear

Stages, DriveConcepts GmbH, 2010.10. MDESIGNgearbox 2010. Design and Calculation Software for Multi-Stage

Gearboxes, DriveConcepts GmbH, 201011. Schlecht, B., M. Senf and T. Schulze. “Beanspruchungsanalyse bei

Stirnradgetrieben, Antriebsstränge in Windenergieanlagen-Haus der Technik,” e.V., Essen, (Refs. 9–10), März 2010.

12. Schulze, Tobias. “Ganzheitliche dynamische Antriebsstrangsbetrachtung von Windenergieanlagen,” Sierke Verlag, 2008, Ph.D. Thesis, TU, Dresden.

13. Schulze, Tobias. “Getriebeberechnung nach Aktuellen Wissenschaftlichen Erkenntnissen, Vortrag Anlässlich des Dresdner Maschinenelemente,” DMK, Dresden, DriveConcepts GmbH, 2007.

14. Schulze, Tobias. “Load Distribution in Planetary Gears under Consideration of All Relevant Influences,” JSME International Conference on Motion and Power Transmissions, May 13–15, 2009, Matsushima Isles Resort, Japan.

15. Schulze, Tobias. “Load distribution in Planetary Gears,” Danish Gear Society Gearteknisk Interesse Gruppe, February 11, 2010, SDU, Odense, Denmark.

16. Schulze, Tobias. “Calculation of Load Distribution in Planetary Gears for An Effective Gear Design Process,” AGMA Fall Technical Meeting 2010, Milwaukee, Wisconsin.

17. Wiche, E. “Radiale Federung von Wälzlagern bei Beliebiger Lagerluft,” Konstruktion, Berlin 1967.

Figure 18 Final design (left side); bad solution with too much lead crowning (right side).

Figure 17 Initial state (left side); first optimization (right side).

Dr.-Ing. Tobias Schulze studied (1996-2001) drivetrain and gear technology at the TU Dresden. From 2001-2006 he was a scientific assistant at the TU Dresden in the analysis of the dynamic behavior of drivetrains with multi-body simulation, including the influence of holes in ring gears with FEM, and the influence of manufactured deviations on bevel gear stress run on a servo-hydraulic test stand for steering systems. Since 2006, Schulze has served as managing director of

DriveConcepts GmbH, Dresden.


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KPCL is a leading manufacturer of gear boxes, known for exceptional product innovation, integrity as well as superior service.

The extensive KPCL product line including standard gear box along with tailor gear box made to suit the individual requirements of customers, has propelled ahead companies in such sectors as Cement, Power, Rubber, Paper & Mining.

Widely regarded as world leaders in Helical Reduction Gear Boxes, KPCL has continued to enjoy worldwide reputation for crafting exceptionally durable and reliable products through its state of art manufacturing facilities.

The Unrivaled Authorityin Power Transmission Solutions

KIRLOSKAR PNEUMATICS CO LTDTransmission DivisionREGD. OFFICE & WORKS: Plot No.1, Hadapsar Industrial Estate, Pune 41 1 O13,Maharashtra, India.Ph.: 020-26727000 Fax: 020-26870297 / 26870634E-mail: [email protected] Web: www.kirloskarkpcl.com

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Introduction to BearingsStructure and function. A surprisingly large number of bearings can be found all around us. Take automobiles, for exam-ple: there are 100 to 150 bearings in a typical car. Without bearings, the wheels would rattle, the transmission gear teeth wouldn’t be able to mesh, and the car wouldn’t run smoothly.

Bearings are not used only in cars, but in all kinds of machinery—from trains to planes and automobiles and much, much more.

Bearings enhance the functionality of machinery and help to save energy. Bearings do their work silently, in tough environments, hidden in machinery where we can’t see them. Nevertheless, bearings are crucial for the stable opera-tion of machinery and for ensuring its top performance.

The word “bearing” incorporates the meaning of “to bear,” in the sense of “to support,” and “to carry a burden.” This refers to the fact that bearings support and carry the burden of revolving axles.

The two pictures below show the most basic bearings — commonly known as rolling bearings.

Rolling bearings are made up of four elements and have an extremely simple structure:

The basic function of bearings is prin-cipally to reduce mechanical friction. By reducing friction —1. Machinery will run more efficiently.2. There will be less frictional wear,

extending the operating life of the machinery.

3 . Abrasion burn is prevented, thus avoiding mechanical breakdown.

Bearings also contribute to lower ener-gy consumption by reducing friction and allowing the efficient transmission of power. This is just one way in which bear-ings are environmentally friendly.

HistoryThe principle of bearings was known to the ancients, and they were in fact used in building the pyramids in Egypt. The illustration is a replica of a relief depict-ing construction in ancient Mesopotamia, where urban civilization flourished in parallel with that of the Pharaohs’ Egypt.

Later, that famous genius of the Middle Ages — Leonardo da Vinci — came up with an idea for a mechanism that is remarkably similar to modern uses of bearings. The machine-based civili-zation that was born in the Industrial Revolution of the 18th century led to the

development of modern bearings.In 1916 NSK started up in Japan

the first specialist production of bearings. However, it was not until after the end of the World War II that Japan’s bearings technology made substantial progress. 1955 marked the beginning of growth in demand for private automo-biles, in addition to home appli-ances such as washing machines, refrigerators and air condition-ers. In this environment, one of the key characteristics that the

Japanese demanded of these home appliances was quietness. However,

bearings manufacturers outside Japan didn’t place much emphasis on this

requirement; so Japanese manufactur-ers proceeded to build up know-how

Figure 1 Rolling bearing (ball bearing).

Figure 2 Rolling bearing (roller bearing).

Figure 3 Outer ring: the large ring of the outer race.


through research and development efforts based on the objective of developing the world’s quietest bearings. Later, Japanese bearings, renowned for their quietness, were exported to the United States and Europe. Before long they also offered a high degree of durability.

Bearing specifications have been stan-dardized in accordance with international ISO standards. Japanese-made bearings are used around the world for their high performance and high quality. There are said to be around 3 billion bearings made annually in Japan, of which over 40 per-

cent are for automobile use; nearly 30 percent are exported.

Bearings have been developed and improved in a global environment, and results from research into further reducing friction are accumulating all the time, continually anticipating the needs of the times. The ongoing challenge remains to:• Reduce weight• Increase compactness• Lengthen life• Reduce energy requirements• Reduce the impact on the environment

• Bearing Types

Anything that can be called a machine will invariably incorporate bearings. Bearings must fulfill a great variety of needs, and they constantly evolve in response to this. Following are bearing types and their various applications:

Figure 4 Inner ring: the small ring of the inner race.

Figure 5 Rolling elements: Several balls or rollers that are contained in the space between the outer race and inner race.

Figure 6 Cage: Used to fix the position of the rolling elements.

Figure 7 Without bearings, Egypt’s pyramids of the pharaohs may never have gotten off the ground.

Figure 8 Deep groove ball bearing: The most widely used bearing in the world.

Figure 9 Angular contact thrust ball bearing: The rolling element meets the inner and outer ring raceways at a contact angle. This bearing can carry radial and axial loads.

Figure 10 Thrust ball bearing: Capable of handling loads in the axial direction (axial loads), and can support heavy loads.


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The Amazing World of BearingsSize varies from 2 mm to 6 m. Bearings come in all sizes: The world’s small-est — “miniature bearings” — have an inner diameter of 0.6 mm, an outer diam-eter of 2.0 mm, and a width of 0.8 mm. They are used in ultra-compact motors. At the other extreme, there are bearings with an outer diameter of 6 meters that weigh over 15 tons. These are used in giant boring machines that dig tunnels, such as the Euro tunnel linking France and Britain under the Straits of Dover.

400,000 revolutions in one minute. Bearings that can revolve at ultra-high speeds are used in dental drills. These drills incorporate two ultra-high preci-sion bearings with an inner diameter of 3.0 mm, an outer diameter of 6.0 mm a width of 2.0 mm, and incorporating ball bearings with a diameter of 1.0 mm. The bearings revolve at the astounding speed of 400,000 revolutions-per-minute. This ultra-high-speed, together with extreme-ly accurate revolution, almost eliminates vibration in the dental drill, helping to provide safe, comfortable dental treat-ment.

Ball revolves at a speed of 160 m/sec. These bearings are used in the main shaft of a V2500 jet engine in an internation-al passenger airplane. The rolling ele-ments in this bearing revolve at a speed of 160 meters-per-second. This is equivalent to 580 km/h. Next time you fly you can relax as these high-performance, high-speed bearings support the fast, powerful and lengthy operation of jet engines.

Vibration of less than 100 nm. It is no exaggeration to say that the accuracy of machinery is determined by the accuracy of the revolution of the bearings. A bear-ing supports each end of the axis of rota-tion. If there is a large run-out from the center of that axis, you could not expect the machine to operate with high per-formance. The deflection from the cen-tral axis of a computer’s external memory device (hard disk drive) that uses ultra-high-precision bearings is less than 100 nm (one nm is one billionth of a meter). What determines this ultra-high preci-sion is the accuracy of the rolling ele-ments such as balls and rollers.

15 years in space. Bearings are also essential to space development. Such information as weather reports, satel-lite broadcast data and car navigation positioning data come to us from satel-lites orbiting the earth. These satellites have a piece of equipment known as a fly-wheel that maintains them in the correct position and orientation. This flywheel uses ultra-high-precision bearings; such bearings have been patiently revolving in space for the past 15 years.

From –253°C to +500°C. The bearings that are used in the coldest temperatures are those that are incorporated in the liq-uid fuel pumps of space rockets, and they rotate in liquid hydrogen at –253°C. At the other extreme, bearings that operate in a very high-temperature environment include the high-performance bearings used in CT scanners in the medical ser-vice field. Even in a vacuum tube where

X-rays are generated and temperatures reach 300 to 500°C, the bearings contin-ue to revolve, helping us to maintain our health.

The Future for BearingsIn closing, following are some themes on the further evolution of bearings.

Figure 11 Cylindrical roller bearing. The rolling elements are the cylindrical roller type.

Figure 12 Cylindrical roller bearing: Here, too, the rolling elements are the cylindrical roller type. However in this instance the shape of the cage differs from that in the previous example.

Figure 13 Tapered roller bearing: The rolling elements are of the tapered roller type; because the rollers are tapered, this bearing is able to carry combined axial and radial loads.


Figure 18 Bearings such as shown here can revolve at ultra-high speeds and are used in, for example, dental drills.

Figure 14 Self-aligning roller bearing: Has an automatic aligning function to compensate for minute misalignments between the inner and outer rings during operation.

Figure 15 Thrust needle bearing: Used in parts such as compressors that deliver the air in automobile air conditioning units.

Figure 16 Cage and roller: One of several kinds of bearing used in vehicles’ manual transmissions; it is required to be highly durable.

Figure 17 “Miniature bearings,” have an inner diameter of 0.6 mm, an outer diameter of 2.0 mm, and a width of 0.8 mm; they are typically used in ultra-compact motors.

1. Greater energy savings. The smaller a machine becomes, the smaller its components. Further, the smaller a machine becomes, the greater the need for precision becomes, and this could mean that even a small amount of friction could lead to a break-down. Moreover, no matter how small machines become, total energy con-sumption will be large when viewed

on a global scale. In order to pro-duce even greater energy savings, we should continue to seek out even bet-ter ways of reducing friction using bearings.

2. “ Cleaner” credentials. Improving bearing technology can have ben-eficial effects on the environment: a reduction in vehicle exhaust gas emis-sions, for example. Additionally, the vast majority of bearings are made from steel that doesn’t contain any harmful chemical substances; this steel can be recycled into new steel materials. Bearings offer excellent potential as products for recycling and reuse.

3. Comfort. Machines must be agreeable for both people and the environment. In the past, machines have supported improved production; in the future,

there will be demands that machines help society and individuals enjoy more fulfilling lives through educa-tion, medical services, welfare and entertainment. Also, the bearings that are used in those machines may be asked to fulfill functions and roles that differ from the old ones.

For more information:NSK Precision America3450 Bearing DriveFranklin, IN, 46131Phone: (800) 255-4773Fax: (317) [email protected]


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HistoryAs with many new inventions, the first practical single-phase induction motors appear to have been invented in 1885 by Galileo Ferraris, an Italian. Two year later, Nicola Tesla, a Serbian-born nat-uralized citizen of the United States., created the 2-phase induction motor; Tesla was granted U.S. patents in 1887. George Westinghouse employed Tesla for one year to develop the induc-tion motor for his company. The first wound-field, 2-phase AC induction motor product family was announced by Westinghouse in 1892. In 1888, Mikhail Dovilo Dobrovolsky created a 3-phase induction with a squirrel cage motor. GE began developing 3-phase AC induction motors beginning in 1891 under Charles Steinmetz’s leadership. Induction motors continued to evolve in form and use. The 3-phase induction motor is used in the larger horsepower application above 1 hp while the single-phase AC motors were

used in the smaller, below 1 hp applica-tions.

ConstructionThe AC induction motor consists of two major assemblies — rotor and stator. AC power in the form of 60 Hz sinusoidal signals are fed into the 3-phase stator windings. This rotating magnetic field induces a rotor field in the rotor’s shorted (closed circuit) squirrel cage windings. The established rotor field runs at a fre-quency and rotor shaft speed that is not in synchronism with the rotating sta-tor frequency. This condition, defined as slip, results in the rotor shaft speed to be tens of rpm below the induction motor’s synchronous speed (frequency) devel-oped by the stator. The slip value varies between one percent and five percent on most AC induction motors. The 3-phase stator signals establish a series of rotat-ing magnetic vector fields that allow the induction motor to continue to rotate freely without external support.

The single-phase AC induction motor works in a similar manner except it pos-

sesses a second wind-

ing — or auxiliary winding — that allows one to use a capacitor to establish a near 90 electric degrees between the stator winding and auxiliary winding. This action supports continuous rotor and shaft rotation. The housing, end caps and bearings complete the AC motor con-struction that supports the motor’s rota-tion (Fig. 1).

PerformanceThe mechanical output is represented by the motor’s torque vs. speed curves, based first on 60 Hz input voltage and current inputs, and later on a range of input frequencies. The motor’s shaft speed is a function of the number of magnetic poles within the motor. It runs at a no-load speed of almost 3,600 rpm for a 2-pole and 1,800 rpm for a 4-pole. Remember the impact of slip. The AC induction motor’s torque vs. speed curve is highly non-linear. There are three different regions on an AC induction motor’s torque vs. speed curves. They are the near-vertical-rated portion of the curve (Fig. 2). Once the torque speed curve begins to bend horizontally, one reaches the maximum percent torque point — the breakdown point — the AC induction motors speed falls rapidly to stall or zero speed.

For the design A, B, C and D NEMA Mg-1 standard-rated torque-speed curves, only the design D AC induction motor curves can re-start and move up the curve back to the rated torque region. The price for the Design D’s higher start-ing torque performance is much lower

power efficiency. The other three design curves require extra

help to return to the rated torque region.

Current is non-linear; the most current for all four

The Workhorse of Industry:The Induction MotorDan Jones, President, Incremotion Associates


design torque-speed curves is drawn at stall (Fig. 3); the Design B curve is the most popular one today. The AC induction motor was originally designed for applications that have a near-con-stant load. One just plugs the AC induc-tion motor’s power cord directly into the 60 Hz wall outlet for constant speed applications. The motor can self-regulate its speed within ± 20 percent of rated load.

Enter the Variable-Speed DriveThe AC induction motor has a flaw when operating in its normal-rated torque region. At very light application loads, it draws nearly the same current at rated load. Power efficiencies could drop to 35 percent from its rated efficiency of

90 percent to 95 percent, depending on an AC motor’s hp output.

The emergence of the 3-phase adjust-able or variable speed drive (VSD) in the late 1980’s provided the AC motor with a much wider speed operation. The variable speed drive is a solid- state power conversion unit that controls the frequency, voltage and current into a 3-phase induction motor. Typical VSDs can seamlessly vary volts and frequency to eliminate the difficulty in high current and low starting torque in AC induction motors. Field weakening, pulse width modulation (PWM), and current control provides other drive strategies available to be more controllable and to maintain high power efficiency over a variable load.

The AC induction motor is the most popular motor for use in a wide range of speed-based applications. Simple in design and rugged in construction, lower in cost and in maintenance — the AC induction motor continues to domi-nate industrial and powered home appli-cations.

Dan Jones received his BSEE degree from Hofstra University in 1965 and MS in Mathematics at Adelphi in 1969. He has over 50 years’ experience in the design of all types of electric motors and generators from 10 W to 500 kW and has held engineering design, management and marketing management positions at a number of companies. He is recognized as an international authority on electric motors and motion control. He has written 250+ technical articles/papers and held seminars in 10 countries. He is a past member of the board of directors of SMMA and EMERF. He currently is a member of the board of directors of the Motion Control Association (MCA). He is a life member of IEEE and a member of ASME. This article was adapted from his seminar on motor types, which was presented at Motion Control 2013 (October 15–17 in Los Angeles) and at the Motor, Drives and Automation Systems 2014 Show (January

29–30 in Orlando).

A or B

C

D

PERCENT SYNCHRONOUS SPEED

PERC

ENT

TORQ

UE

0 50 100

300

250

200

150

100

50

0

Figure 3

Figure 1

A

BC or D

PERCENT OF SYNCHRONOUS SPEED

CURR

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Figure 2


industry news

TimkenOPENS INDUSTRIAL SERVICE CENTER

The Timken Company recently announced the opening of its new industrial service center in Raipur, in the state of Chhattisgarh, India. The 30,000-square-foot facility provides gear drive and bearing repair and upgrade services to meet growing customer demand in central India.

“We are pleased to open a dedicated service center with advanced inspection techniques and machine tools that can promptly diagnose and repair our customers’ mission-critical

equipment,” said Carl Rapp, Timken vice president of industrial services. “The Raipur facility offers a ‘one-stop-shop’ solution to our many customers in India’s growing cement, primary metals, mining and power generation sectors.”

The Timken Company has been steadily expanding its indus-trial services portfolio within the process industries segment, adding to its existing bearing repair capabilities and leveraging recent related service acquisitions, which include gearbox repair and motor rewind, to further expand the geographic footprint of the services business. The Raipur center is the company’s first industrial service center in India to offer gear repair, and joins the Timken facility in Jamshedpur, India, as the second offering bearing repair. Timken also operates production bear-ing facilities in Chennai and Jamshedpur, as well as a research and technology center within its Bangalore headquarters.

SPC Automation IndiaPROVIDES PLATFORM FOR INDUSTRIAL AUTOMATION

Messe Frankfurt Trade Fairs India together with Mesago Messe Frankfurt introduces Europe’s leading automation exhibition SPS IPC Drives to the Indian market. The organisers feel it is the perfect time to harness business opportunities across all verticals of the automation industry in India and believe the launch of ‘SPS Automation India - Driving manufacturing pro-cesses of the future’ will be the ideal platform to aid this devel-opment.

The trade fair, like the mother event SPS IPC Drives (Nuremberg), will represent a leading platform for innova-tions in the field of industrial automation and host a vast range of displays of products, systems and services. SPS Automation India will be held from 5 – 7 February 2015 at Mahatma Mandir Convention and Exhibition Centre in Ahmedabad, Gujarat.

In India, industrial automation is an inherent need as well as a market requirement. Raj Manek, managing director, Messe Frankfurt Trade Fairs India stated: “The solution to India’s pur-suit of being a world-class industrial competitor is automation, and we are confident that SPS Automation India will present the sector players the perfect platform to showcase technolo-gies while allowing the Indian market to access automation solutions designed to improve business profitability and opti-mize manufacturing operations. Moreover, we are also proud to combine strengths with our brand partner Mesago.” For regis-tration information, visit www.spsautomation-india.in.


GEHELPS POWER INDIA’S FIRST DIESEL-ELECTRIC SHIP

India continues to grow as a global center of tech-nological excellence, accounting for 10 percent of research and development and home to five of the top 10 science and technology schools in Asia. The Government of India, having a network of more than 50 laboratories deeply engaged in developing a range of technologies from electronic and computer sci-ences, through life sciences and materials, to marine research and development, will invest in a new sci-entific research platform vessel to be built by Bharati Shipyard, based in Mumbai. The Class XII merchant vessel will host scientists from various Indian govern-ment scientific laboratories. It will be used to carry out multipurpose research along the coastal sea belt of India.

Bharati has chosen GE Power Conversion, with its extensive experience and understanding of the global marine industry, to supply the power and propulsion system for the ship. This will be the first diesel-elec-tric ship built in India to incorporate medium-voltage equipment, an area in which GE already has a strong position globally. Delivery of the vessel is expected in the year 2015.

Paul English, marine business leader for GE Power Conversion says, “GE has built up a good reputation in India over many years, and this has clearly helped us to win this interesting new contract. The people at Bharati know they can trust us to deliver with a medi-um-voltage propulsion system that will be unique in Indian waters. They also know that we are very good at accommodating application-specific needs into individual projects, according to each customer’s unique situation.”

“We are also very happy to gain the Government of India as the final end user of this type of medium-voltage diesel-electric propulsion vessel for the first time, and we will be working hard to make sure it is not the last,” English added. “We have been working on this project for two years, and I think it is fair to say that all parties are very satisfied with the outcome. Overall, we see good prospects for power and propul-sion systems in India in the marine industry.”

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Enhanced Induction Hardening of Gears and ComponentsMorphology of MicropittingProgress in Gear Milling

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industry news

SiemensDELIVERS SOUND START TO 2014

Siemens delivered a sound quarter to start its fiscal year 2014. Supported by several major orders, new orders rose 12 per-cent year-over-year, while revenue development was nearly stable. “We delivered a sound quarter to start our fiscal year. As expected, market conditions were not in our favor. We continue to focus on our productivity program for the year, and on the actions we will take beyond 2014,” said Siemens president and CEO Joe Kaeser.

Excluding currency and portfolio effects, new orders at Siemens increased in the first quarter of fiscal 2014 12 per-cent to €20.8 billion. At €17.3 billion, revenue was one percent below the prior-year level. The book-to-bill ratio was 1.20. The order backlog at the end of the first quarter again reached the record level of €102 billion. Total Sectors profit was up 15 per-cent to €1.8 billion, while the Sectors’ profit margin rose to 10.2 percent, compared to 8.6 percent in the prior-year quarter. Net income increased to €1.5 billion from €1.2 billion. Earnings per share climbed to €1.70 from €1.42.

Sector overviewNew orders at the Energy Sector increased three percent to €7.2 billion in a market environment that remained highly com-petitive. While declining at the Power Generation and Power Transmission Divisions, new orders doubled at the Wind Power Division. Revenue at the Sector declined four percent to €5.8 billion. Due in part to lower charges compared to the prior-year quarter, profit at the Sector improved to €506 million from €410 million, while the profit margin rose to 8.8 percent from 6.5 percent a year earlier.

The Healthcare Sector contributed €471 million to profit in the first quarter, compared to €503 million in the first quarter of the prior year. The decrease includes burdens on profit from currency effects. The Sector also faced ongoing market chal-lenges, including weak economic conditions in Europe, uncer-tainty in the healthcare market, an excise tax on medical devic-es in the U.S. and slowing growth in China. The profit margin was 15.2 percent, compared to 15.5 percent in the prior-year

quarter. New orders at the Sector climbed four percent to €3.2 billion and revenue increased one percent to €3.1 billion.

At the Industry Sector, new orders rose ten percent to €4.6 billion, driven by a substantially higher volume from major orders in the Sector’s long-cycle businesses. At €4.3 billion, revenue remained at the prior-year level. Profit was down five percent to €482 million. Profit increased at the Industry Automation Division while declining at the Drive Technologies Division. The profit margin at the Sector was 11.2 percent, compared to 11.5 percent in the prior-year period.

At the Infrastructure & Cities Sector, new orders soared 45 percent, driven by a major order totaling €1.6 billion for two driverless subway lines in Saudi Arabia to be supplied by the Sector’s Transportation & Logistics and Power Grid Solutions & Products businesses. Revenue increased four percent year-over-year to €4.4 billion. Profit at the Infrastructure & Cities Sector climbed to €330 million from €141 million in the com-parable period a year earlier, supported by profit increases in all the Sectors’ businesses. Improved project execution at the Transportation & Logistics business was a key factor. The profit margin rose to 7.6 percent, compared to 3.4 percent in the pri-or-year period.

HSBCOFFERS PROMISING DATA ON MANUFACTURING REVIVAL

Operating conditions for India’s manufacturers improved fur-ther in January, according to the HSBC India Manufacturing Purchasing Managers’ Index (PMI). The index, fuelled by higher output and strong orders, rose to 51.4, from 50.7 in December – the highest reading since March 2013. However, the pace of expansion was below the series average of 55.1. New orders expanded at the fastest rate for ten months, helped by an improvement in new export business. Output rose for the third consecutive month, with respondents citing new con-tracts as the main reason for increased production levels. Leif Eskesen, chief economist for India and ASEAN, HSBC, said: “Manufacturing activity moved into a higher gear led by faster growth in new orders. However, inflation pressures also firmed, suggesting that the Reserve Bank of India has to keep up its inflation guards.”

The survey suggests that consumer and intermediate goods were behind the recent expansion, but that capital goods pro-duction softened. Backlogs of work continued to rise but at a slightly slower rate, probably helped by stronger employment growth. Purchasing activity picked up at the start of 2014, in line with the rise in order flows. Average input costs increased, with manufacturers reporting that higher prices for raw mate-rials were passed on to customers. Manufacturing activity moved into a higher gear led by faster growth in new orders. The HSBC India Manufacturing PMI is a composite indicator designed to provide an overall view of activity in the manufac-turing sector. A reading above 50 signals improvement, while below 50 signals deterioration.


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March 19–22—WIN Eurasia Automation 2014. Istanbul, Turkey. The world’s leading trade show for high-growth automation technology, electrotech, hydraulics/pneumatics and material handling. More than 86 unions and associations come together to provide new market opportu-nities in Asia, the Middle East, Africa and the Balkans. Main topics include assembly, robotics, controls, sensors, measuring systems, IT and software, laser technology, automation systems and services, packaging, cranes, transportation, hydraulics and pneumatics, gears, motors, transformers and much more. The 2013 show welcomed professionals from more than 77 coun-tries particularly in the machinery, energy, automotive and metal sectors. For more information, visit www.win-fair.com.

April 7–11—Hannover Messe 2014. Hannover Fairgrounds, Hannover, Germany. The world’s leading trade show for industrial technology returns in 2014 with a full lineup of trade shows under the banner “Integrated Industry-Next Steps.” The seven co-located shows include Industrial Automation; MobiliTec; Digital Factory; Industrial Supply; IndustrialGreen Tec and Research and Technology and Energy. The Netherlands is the official partner country in 2014. Discover new perspectives on energy, automation and indus-trial supply and engineering topics as well as a broad range of events and displays affecting the global industrial market today. Other Hannover highlights include the Robotics Award, the 11th WoMenPower Conference, Metropolitan Solutions, economic forums, job and career fair and more. For more infor-mation, visit www.hannovermesse.de.

April 9–11—Pump, Valve & Compressor Expo 2014. Chennai. Pumps and valves are the integral part of any process where a transportation of liquid is required. Over the years, the usage of pumps, which was primarily for water, has undergone a total change and now there are pumps available for every material which needs to be moved. Along with pumps, the technology for valves and associated control equipment has also changed considerably. Exhibitors include companies involved in shafts/seals, motors, gearboxes, couplings, bearings, actuators, sensors and more. A separate Compressor Pavilion will be available to attendees as well as a special focus on solar powered pumps. For more information, visit www.cii.in.

April 19–21—Indian Machine Tool and Automation Expo. New Delhi. This event provides a plat-form for manufacturers or suppliers of machine tools and auto-mation products to display their products before a professional community dealing with machine tool, automation, cutting tool and commercial consumers. It will be a forum for discussion and demonstration of machine tool and automation. Exhibition categories include lathes, boring machines, drilling machines, forging, grinding, machining centers, machine tools, abrasives, measuring equipment, tooling, industrial cleaning and more. For more information, visit www.toolautomationexpo.com.

May 5–7—Renewable Energy World Conference & Expo. New Delhi. Under the theme, “Power: Key to India’s Future Growth,” the event brings together decision makers and influencers as well as technical experts and professionals from leading companies involved in the renewable, conventional, hydropower, transmissions and distribution power generation, within India and around the world. With a track record attract-ing more than 7,000 attendees from 40 countries around the globe, the event is co-located with Power-Gen India & Central Asia, DistribuTech India and incorporating HydroVision India. The show will focus on the ways to prevent useless wastage of energy and will discuss about the effective mediums which will help in protecting India’s energy future. For more information, visit www.renewableenergyindiaexpo.com.

May 9—Manufacturing IT Summit. Mumbai. The 5th edition of the Manufacturing IT Summit is highly focused and designed for IT leaders in the manufacturing sector to present global case studies, benchmark business strategies and ensure that your manufacturing facility has a coherent, logical IT strat-egy. Face-to-face networking opportunities, keynote presenta-tions and executive exchanges will help give a clear understand-ing of the issues and challenges faced in this industry today. This is one of the largest gatherings in India of CIOs and more than 200+ delegates from the manufacturing sector. Topics include cloud security, data virtualization and overcoming the legacy cri-sis. For more information, visit www.mitsummit.com.

May 29–31—Automotive Engineering Show 2014. Pune. The 8th edition will focus on “Lowering Costs in Automotive Plants.” This event centers on the automotive manufacturing processes with the automobile factory as its focal point. Featuring more than 120 exhibitors, Automotive Engineering will present solutions to an audience of 6,000+ users from the auto industry. Exhibition categories include automation systems, assembly line systems, machining centers, robotics, metrology, material handling, productivity enhanc-ers and more. Exhibitors can increase sales leads, develop new market shares, launch new product/services and expand com-petitor advantage. Senior executives will present their thoughts and debate on the current manufacturing scenario and future trends. For more information, visit www.aes-show.com.

June 11–14—Pack Plus 2014. New Delhi. This event will include a packaging zone, converting zone, processing zone and supply chain zone and include important decision makers and specifiers from top and middle management from various industries including pharmaceutical and chemical, food and beverage, dairy and meat, engineering, garments and textiles, personal care products and logistics. Printers, converters, packaging professionals and packaging end users as well as the providers of materials, equipment and services will also visit in large numbers. Relevant industrial subjects will include auto-mation, barcodes, smart cards, biometrics, RFID, bulk packaging and more. For additional information, visit www.packplus.in.


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“ According to the law of Dharma, you have a unique talent and a unique way of expressing it. There is something that you can do better than anyone else in the whole world — and for every unique talent and unique expres-sion of that talent, there are also unique needs. When these needs are matched with the creative expression of your talents, that is the spark that creates affluence. Expressing your talents to ful-fill needs creates unlimited wealth and abundance.” — Deepak Chopra

Consider it a call-to-arms for the Indian government to overcome their atrophy and begin addressing India’s vast, yet underdeveloped, potential workforce. Also: now is the time to sharpen the pencils, get the slide rules out, and develop a mas-ter plan to tackle a woefully lacking national infrastructure to help attract international businesses—businesses that look longingly at India from afar, licking their collective lips while wishing the country would get its act together. What makes this all the more an “in the moment” issue is a China whose knees are buckling. But if India continues its dithering, there is a real possibility of a lost, historical moment on a grand — if not eco-nomically tragic — scale.

And yet there’s good news as well.Witness: Electrical equipment maker Havells is one of several

Indian companies to have shifted production or sourcing from China. That cudgel in the form of cheap labor and cheap energy that China has wielded for the last 25–30 years has begun to rot and splinter. Apparently the seeds of a Middle Class are taking root there and the workers are demanding equal pay for an equal day’s work, and so on. And easy-access electricity?—there is less of it—the world’s worst polluter notwithstanding.

So Chinese manufacturers passed the hot potato on to their customers, such as in India, and raised prices by as much as 20 percent. This went on for quite a while. But, as quoted in a piece from a recent businesstoday.com article, “A time came when we said this was enough, and we should look at manufacturing in India,” says Sunil Sikka, Havells president.

It gets better.Consumer appliance company Godrej and consumer appli-

ance company/auto parts maker Bosch have started expanding or exploring manufacturing operations in India.

And get this — Chinese companies are scrambling aboard the bandwagon, looking for their piece of the pie. Business Today, a prime source for this article, interviewed 16 companies that tran-sitioned at least part of their business (production) to India.

“Chinese costs are going up; this is a great time to move pro-duction from China to India,” says Adi Godrej, chairman of the Godrej Group, in the same Business Today article. His company has shifted its air conditioner and washing machine production to India. And while Godrej believes the trend will continue for 20 years, the time to get those roads, bridges, electrical and other infrastructure needs built is now.”

Unfortunately, as India’s efforts at building a Middle Class fall short, so too does its manufacturing base and national economy. And despite the country’s brisk export activi-ty, it will take more than an election to move mountains and lay wire. Fact is, there simply are not enough p e o p l e i n India with dis-posable income to buy air con-ditioners or cars or washing machines or refrig-erators, and so on, to sus-tain—much less help create—a sound domestic economy. By the end of 2013, the share of manufacturing in India’s gross domestic product dropped to its lowest in a decade.

But even if there were enough consumers, there’s this—take ACs for example. Chances are they would be off more often than on, given the state of the country’s elec-trical supply.

On this matter of infra-structure, an expert no less than economist and Nobel laureate Joseph Stiglitz worries for India — worries whether she has the wherewith-al — and the will — to do what it must to assume what should be its logical place in the world’s manufac-turing pecking order.

As Stiglitz explains, “If you don’t have electricity or have high cost of electricity, it will not help manufacturing — even if labour is cheap. I do worry that there are certain things, like lack of infrastructure, that are impediments for some kinds of manufac-turing that would have otherwise come to India,” he says.

So there you have it. Let India’s manufacturing renaissance begin—now.

All that is needed is a level playing field for the “games.”And if you (India) build it, they (manufacturers) will

come — in droves.

India’s Economy: Moving Mountains or Cursing the Darkness?


INsight

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Gear Technology India 2014 # 1

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