INDIA’S GEAR AND POWER TRANSMISSION …€™S GEAR AND POWER TRANSMISSION RESOURCE ... Shanthi...

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® INDIA January 2012 geartechnologyindia.com Premier Issue Premier Issue INDIA’S GEAR AND POWER TRANSMISSION RESOURCE Feature Articles IPTEX 2012 Universal Gear Milling Software Profie: Shanthi Gears Gear Software for Design Optimization Shot Peening Technologies Technical Articles Manufacturing Spiral Bevel Gears on a Machining Center Synchronous Motors Optimizing Gear Lug Root Fillet Radius Wind Turbine Gearbox Development Plus: INsight A regular column written by Indian experts in the gear and power transmission fields

Transcript of INDIA’S GEAR AND POWER TRANSMISSION …€™S GEAR AND POWER TRANSMISSION RESOURCE ... Shanthi...

®® INDIA

January 2012

geartechnologyindia.com

PremierIssue

PremierIssue

INDIA’S GEAR AND POWER TRANSMISSION RESOURCE

Feature Articles• IPTEX 2012 • Universal Gear Milling Software• Profi e: Shanthi Gears• Gear Software for Design

Optimization• Shot Peening Technologies

Technical Articles• Manufacturing Spiral

Bevel Gears on a Machining Center

• Synchronous Motors

• Optimizing Gear Lug Root Fillet Radius

• Wind Turbine Gearbox Development

Plus:INsightA regular column written by Indian experts in the gear and power transmission fi elds

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January 2012

C O N T E N T S

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Manufacturing Method of Large-Sized Spiral Bevel Gears in a Cyclo-Palloid System Using Multi-Axis Control and Multi-Tasking Machine ToolPrecision machining of complicated shapes witha multi-axis machining center and standard tooling.

Motoring AheadSynchronous motors controlled by variable-speed drives are bringing higher efficiencies to industrial applications.

Optimizing Gear Lug Root Fillet RadiusFEA and software analysis allow optimization of critical powertrain component. Comparison of Test Rig and Field Measurement Results on Gearboxes for Wind TurbinesTest rig vs. field gearbox measurement; multi-body analysis for calculating and simulating gearbox behavior.

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F E A T U R E S

T E C H N I C A L A R T I C L E S

18 Gear Pro Software Extends turning and milling machines

20 Profile Shanthi Gears Ltd.

24 Optimization with KISSsoft’s Gearing Variant Generator

44 Shot Peening Technologies Enhance component integrity

12 IPTEX 2012 What to expect from exhibitors at this year’s International Power Transmission Expo–a Gear Engineering Event

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January 2012

C O N T E N T S®® INDIA

D E P A R T M E N T S

6 Publisher’s Page Your gear and power transmission resource

8 Product News The latest gear and power transmission technology.

51 Subscriptions Fill out this form to continue your FREE subscription.

52 Industry News What’s happening in the Indian gear and power transmission industry.

54 Calendar Exhibitions, technical seminars and other educational events.

55 Advertiser Index How to contact advertisers in this issue.

56 INsight IPTEX and Gear Technology India.

Cover photo showsa ground spiral bevel gear and pinion, a highly specilalized type of precision gear set.Courtesy of Bevel Gears India.

On The Cover

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January 2012

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PremierIssue

PremierIssue

INDIA’S GEAR AND POWER TRANSMISSION RESOURCE

Feature Articles• IPTEX 2012 • Universal Gear Milling Software• Profie: Shanthi Gears• Gear Software for Design

Optimization• Shot Peening Technologies

Technical Articles• Manufacturing Spiral

Bevel Gears on a Machining Center

• Synchronous Motors

• Optimizing Gear Lug Root Fillet Radius

• Wind Turbine Gearbox Development

Plus:INsightA re-occuring column written by Indian experts in the gear and power transmission fields

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® INDIAIndiaWWW.Sandvik.Coromant.Com/in

The ring gear to the right takes 20% less time to machine.

How is that possible? Coromill®170 is a high performance cutter for large gears in module range 12-22. In combination with our latest grades, your gear machining simply is more effi cient, leaving minimal and even allowance for subsequent operations. Use it for precision and reliability in roughing of external and internal gears.

Sound interesting? Go to our site or, better yet, get in touch with someone in a yellow coat.

Can you see the difference?

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January-March 2012

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Capital Tool Industries7-a, Industrial Estate

Patiala 147004, INDIAPh:+91-175-2351089, 2352326

Fax:+91-175-2217102e-mail: [email protected]

www.capital-tool.com

CTI is a long established company producing quality Gear Cutting Tools since 1966. We specialize in the manufacture of Gear Hobs up to 40 Module in Class AA, A and B, Spline and Worm Gear Hobs, Gear Shaper Cutters, Gear Shav-ing Cutters, Broaches and Milling Cutters for various application.

capitalTOOL INDUSTRIES

ISO 9001:2008 Company

PrecisionGear Cutting

ToolsGEAR 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 pur-pose of establishing Indian editions of foreign technical journals.

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

Editorial StaffMichael Goldstein, Publisher & Editor-in-ChiefWilliam R. Stott, Managing EditorJack McGuinn, Senior EditorMatthew Jaster, Associate Editor

Advertising Sales (International)Michael Goldstein, Publisher & Editor-in-ChiefDave Friedman, Sales Manager

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 PublicationsNo. 132, 1st Floor, 5th CrossCambridge LayoutBangalore 560 008IndiaPhone/Fax: + (91) 80-25567028/29+ (91) 80-41493996/[email protected]

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

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 infor-matory and not specific.

GEAR TECHNOLOGY® is a registered trademark of Randall Publications LLC, and application for registering GEAR TECHNOLOGY® India™ as is a trade-mark of Randall Publications LLC is pending. The contents of this publication are Copyright Randall Publications LLC, 2012. All rights are reserved. For per-mission to reprint any portion of this magazine, contact the publisher at the USA Headquarters office, listed above.

Advertising and subscription information is available at www.geartechnologyindia.com

• Gear and Tool Design Software• Analysis and Optimisation• Machine Simulation and Inspection• Failure Investigation• Bespoke Software Development• Training and Support

[email protected]

Gear Production SuiteGear Production Suite

MEMBER OF

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P U B L I S H E R ' S P A G E Your Gear and Power Transmission Resource

Just over a year ago, I had the great pleasure to visit India for the first time. I experienced its culture, learned some of its history and visited sites both ancient and modern. I savored the food and flavors and enjoyed my chance to meet old friends and make new ones. I visited India a second time several months ago, and by the time you read this, I’ll be there again.

I intend to keep coming to India—both in person, and in the form of this new maga-zine. After months of hard work and coopera-tion, we’re extremely proud to present to you the first edition of Gear Technology India.

Many of you may be familiar with our magazines Gear Technology and Power Transmission Engineering, both of which are published in the United States. Gear Technology India is similar to the other two, but also different in important ways. It’s simi-lar in its content and educational focus, but different in that this magazine is designed exclusively for an Indian audience. This is your magazine.

Our goal for Gear Technology India is to replicate much of the style and philosophy that have made Gear Technology and Power Transmission Engineering the most respected magazines of their kind around the world. We will provide an educational venue for gear and power transmission manu-facturers, buyers and end users. We aim to help you at your craft, with articles that show you the latest in technology and design. We will bring you the best and most important research from around the world—technical articles on the design, process, manufacturing, heat treating, testing, assem-bly, purchase, lubrication and use of gears. We’ll also give you insight into the design of mechanical power transmis-sion systems with articles on gearboxes, bearings, motors, clutches, couplings, belt drives, chain drives and other com-ponents.

In addition, Gear Technology India will provide you with the latest news, information and insight regarding these industries in India.

India’s manufacturing sector is vibrant, diverse and growing in importance to the global marketplace. Gear and power transmission products play a vital role in the health and success of Indian industry. We envision Gear Technology India taking a central role in the continued suc-cess and growth of these industries.

I’d like to take this opportunity to thank all of those who have helped us bring this magazine to fruition. Most nota-bly that includes our partners, Virgo Publications, the sister company to Virgo Communications & Exhibitions Pvt. Ltd. Virgo has been instrumental in helping us to ensure that this magazine truly serves the Indian marketplace.

It’s also important to recognize that no magazine can

be a success without the sup-port of its advertisers. So I’d like to thank all of those who have helped us bring this f irst issue to press: Capi ta l Tool Industr ies , Dontyne Systems, ESGI Tools Pvt. Ltd., Essential Power Transmission Pvt. Ltd, Gleason Corporation, Hangsterfer’s Laboratories, H a n s - J u e r g e n G e i g e r , Höfler, Ipsen International, Kapp-Niles, MAG India, Reishauer AG, Sandvik Coromant, Sicmat S.p.A., SKF and Tool Masters India.

If your company is a supplier in the gear and power transmission indus-tries, this magazine could

help you communicate with your customers. To join our list of advertisers,

please contact Anitha Raghunath at Virgo Publications in Bangalore ([email protected]) or Dave Friedman at our USA office ([email protected]).

Finally, I’d like to thank you, our readers, for picking up this magazine and reading it. Without your participation, none of the rest of what we do has any purpose. With that in mind, I’d like to ask for your help. As I said above, this is your magazine. You can make it truly yours by participating directly in a variety of ways:

Write articles for us. Send us your news items. Respond to one of the articles in this issue with a letter to the editor. Even if you can’t contribute articles, you can still help. Give us feedback or send us ideas about how we can best serve you in the future.

If you need ideas about how you can help, please visit www.geartechnologyindia.com/contribute.php, where we’ve posted a list of different ways you can contribute. No mat-ter how you’d like to contribute, you can always send your contributions to our managing editor, Randy Stott, at [email protected].

If you haven’t already done so, please fill out the sub-scription card on page 51, or visit www.geartechnologyindia.com/subscribe.php to complete one online.

We’ve made every effort to provide value for you in these pages. So most of all, we hope you just keep reading.

Sincerely,

Michael Goldstein, Publisher & Editor-in-Chief

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PremierIssuePremierIssue

INDIA’S GEAR AND POWER TRANSMISSION RESOURCE

Feature Articles

• IPTEX 2012

• Universal Gear Milling Software

• Profie: Shanthi Gears

• Gear Software for Design

Optimization

• Shot Peening Technologies

Technical Articles

• Manufacturing Spiral

Bevel Gears on a

Machining Center

• Synchronous Motors

• Optimizing Gear Lug

Root Fillet Radius

• Wind Turbine Gearbox

Development

Plus:INsightA re-occuring column

written by Indian experts

in the gear and power

transmission fields

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P R O D U C T N E W S P R O D U C T N E W S

Kudale

OFFERS VARIETY OF GEAR ROLL TESTERS

Kudale Instruments Ltd. is an ISO 9001-2000 certi-fied, technology-driven organization engaged since 1974 in manufacturing precision measuring instruments and testing equipment. The products manufactured are for force, torque and dimensional measurement applications and calibration solutions. Kudale has recently released several new prod-ucts, including double-flank gear roll testers, bevel gear testers and computerized gear roll testers.

Double-Flank Gear Roll Tester. The demand for faster and quieter running gears, coupled with the fast depleting energy and increase in cost, has necessitated high effi-ciency power transmission. Precise gear measurements are therefore essential for quality control. The double-flank roll testing of gears is an important inspection method in producing quality gears. Kudale offers different models of double-flank gear roll testers; i.e., Model P-0, P-1 and P-2. The equipment consists of an accurately machined, solid, robust cast base which carries fixed and measuring slides, and ensures accuracy, repeatability and fine movement without play and friction. The measuring slide is fitted on linear guideways, thus ensuring excellent roll test accuracy. The displacement of a measuring slide can be read from the dial indicator connected to the measuring slide. The equip-ment is used to check the total composite error, tooth-to-tooth error, etc. With the basic equipment, bore-type spur and helical gears are inspected, and optional accessories for checking shafted gear, worm and bevel gears are available. Different models are offered to suit gears with CD 25 to 350 mm, and shafted gears up to 700 mm shaft length.

Model DO-0. Kudale’s gear roll tester, the Model DO-0, facilitates gear inspection, particularly smaller dimensions.

It is a suitable device for checking the metallic as well as plastic gears with highly sensitive and accurate mecha-nisms. The instrument is useful for inspection of gears by double-flank method—tooth-to-tooth error and tooth-to-tooth composite error. The basic unit consists of two major sub-assemblies. The right side includes the treated machine base with gauge finish ground vee and reciprocal top slide. The machine base is treated for dimensional stability. The top slide is precision engineered and includes a special bearing mounted mechanism with lead screw and handle. The assembly also provides the ability to set the desired measuring pressure. The left slide is also fitted on vee verti-cally, allowing it to be positioned at the desired height as per requirement. The component gear is mounted on the arbor at the right side and, similarly, the master gear or mating gear on the left side. Both gears are meshed and rotated. The deflection due to composite error or tooth-to-tooth error is indicated on the dial gauge. Mechanical, (DO-0) Motorized (DO-0M) and full automatic computerized models DO-0PC are also available.

The Bevel Gear Tester. This product is a unique solu-tion for testing bevel gear assemblies during production and final inspection. The tester allows adjustment of production machines for bevel gearing and bevel gears assembly. Such

Product News brings you the latest in technology for the gear and power transmission industries. We welcome your submissions. Please send new product announcements via e-mail to [email protected].

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computerized gear roll tester is the latest in the series of mod-els of double-flank gear testers. The instrument consists of robust, basic instruments including gear driving mechanism, digital indicating unit/control unit, high precision linear mea-surement probe, motor drive unit and user friendly software. The test report also can be printed on a dot matrix printer from digital indicating and through a printer port. The models CGRT, P-1 and CGRT, P-2 are offered to suit gears with CD 60 to 350 mm and shafted gears up to 700 mm shaft length. A high spot marking mechanism is also available.

For more information:Kudale Instruments Ltd.98A/17 Hadapsar Industrial Estate,Pune 411 013 Phone: +(91) 20 2687 0567www.kudaleinstruments.com

testing is necessary because it helps shorten the setup time and secures the assembly dimensions. The equipment is also useful for measuring the clearance of bevel gear flanks and the detection of bearing areas, measuring of composite error by double-flank rolling tests, checking of assembly distance and backlash measurement. The instrument consists of a precisely machined, rigid cast iron, semi-circular base with two swiveling arm assemblies. The arm assemblies revolve around the bush mounted on the base; the rotors are mount-ed in cylinders of arm assemblies and actuate on spring pressure. The setting mandrel is mounted in the bore of the bushing on the base to set the assembly distance. For testing a pair of bevel gears, suitable mandrels are required for for mounting on the rotor’s bore. The calculated slip gauge is used for setting the specified assembly distance. By rotating the assembly, the inspection results can be seen on dial indi-cators. The maximum bevel gear diameter is 140 mm and assembly distance 90 mm. The extended capacity model is also available.

Computerized Gear Roll Tester. This instrument is useful for checking total composite error, (TCE) tooth-to-tooth error (TTE) and radial runout error of spur and helical gears. The

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P R O D U C T N E W S P R O D U C T N E W S

Parker RELEASES LATEST AC VARIABLE SPEED DRIVE

Parker Hannifin Corporation recently unveiled the lat-est addition to its AC variable speed drives range. The AC30V is the first of an entirely new generation of drives products from Parker and has been designed specifically to meet the rigorous demands of industrial pump, fan and general purpose applications. Initially available in three frame sizes with standard dual mounting options of either IP20 backplate or through-panel mounting, the AC30V will cover the power range 0.75 kW to 18.5 kW (variable torque rating). Fully enclosed IP55 and coldplate mount versions, along with extended power capabilities up to 110 kW, will be introduced progressively. Its modular design has enabled Parker to create an AC30V Series which will evolve to include customized variants for complex process or special-ized applications. This modularity also reduces the inven-tory requirements and associated costs for the end user.

For more information:Parker Hannifin India Pvt.Ltd.Plot EL-26, MIDCTTC Industrial Area Mahape Navi Mumbai 400709 IndiaPhone: +(91) 02-2651370818www.parker.com

Schaeffl er AG IMPROVES BELT DRIVE EFFICIENCY

The overrunning alternator pulley is one of the unsung heroes in the field of modern engines. The overrunning alternator pulley is the functional interior of the belt pulley located on the generator. The overrunning alternator pulley decouples the alternator from the rotational irregularities of the crankshaft of an internal combustion engine. It therefore performs a task that must not be underestimated, because the rotational irregularities that occur in modern internal combustion engines are significantly higher than those indi-cated to the driver by the tachometer needle.

The generator is the component with the greatest mass moment of inertia and the highest speed in the accessory drive. This means that the acceleration and deceleration forces acting on the generator resulting from the rotational irregularity have the greatest effect on the belt transferring these forces. The overrunning alternator pulley ensures that at many operating points only the accelerating proportion of the crankshaft forces that are transferred to the belt drive are used to drive the alternator. The advantages of the alternator pulley with a one-way clutch, also called an OAP (overrun-ning alternator pulley) in the trade, are clear. The reduction in the force level in the belt drive increases the life of indi-vidual components while ensuring an increase in the genera-tor speed and a reduction in noise. In addition to increased smoothness, the overrunning alternator pulley makes a con-tribution to reducing fuel consumption and CO2 emissions.

For more information:Schaeffler Group (FAG Bearings India Limited)710, 7th Floor, Phase II, Spencer Plaza769-Anna SalaiChennai 600 002 IndiaPhone + (91) 44 28 4935-82Fax + (91) 44 28497577www.fag.com

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Bonfi glioli

PRESENTS HYBRID DRIVE SOLUTION

Bonfiglioli Riduttori SpA, the Bologna-based leader in power transmission for mobile and self-propelled machines recently presented a new hybrid drive solution for agricul-tural sprayers (crop irrigation and treatment machines). The new drive has been developed in co-engineering with the powertra in division of Magneti Marelli.

Bonfiglioli’s experience in hub drive gears for earth moving, road surfacing, farm and construction machinery, combined with Magneti Marelli’s experience in the design of strategic components for electric and hybrid drivetrains, has led to the development of an innovative solution for this type of application, in which flexibility, compactness and performance must meet strict requirements. The drive’s electric motor is fully integrated in a gear unit designed by Bonfiglioli, especially for this type of agricultural applica-tion.

Thanks to the high level of integration between the Bonfiglioli gear unit and the Magneti Marelli motor, the new drive boasts extremely compact dimensions. This is a funda-mental requirement for sprayers, whose drive systems must not damage crops during operation in the field. Use of an electric drive system instead of a conventional hydraulic one guaran-tees a high level of flexibility and allows all four wheels to be driven independently. It also permits use of a kinetic energy recovery system to generate energy, when the machine is trav-elling downhill, for example, thus reducing impact on the envi-ronment in terms of pollution and emissions.

For more information:Bonfiglioli Riduttori S.p.A.Via Giovanni XXIII 7/a40012 Lippo di Calderara di RenoBologna, ItalyPhone +(39) 051 647 [email protected]

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IPTEX 2012, taking place from February 9–11, 2012 at the Bombay Exhibition Center in Mumbai, offers the latest prod-ucts and technologies in the gear and power transmission fields. Following its successful debut in 2010, IPTEX provides a destination for industrial end users and power transmission manufacturers to share insights on the future of manufacturing in India. Here’s a quick look at some of the exhibitors that will be on hand to discuss the products and services offered to the Indian market:

Hexagon Metrology offers a broad range of products for every industrial metrol-ogy application (courtesy of Hexagon Metrology).

A Focus on India’s Growing Industrial MarketMatthew Jaster, Associate Editor

Hexagon Metrology is part of the Hexagon AB Group and includes metrology brands such as Brown and Sharpe, Cognitens, DEA, Leica Geosystems (Metrology Division), Leitz, M&H Inprocess Messtechnik, Optiv, PC-DMIS, Quindos, Romer and Tesa. Hexagon Metrology brands represent millions of coordinate mea-suring machines (CMMs), portable measuring systems and handheld instruments, and tens of thousands of metrology software licenses. The com-pany offering of machines, systems and software is complemented by a wide range of product support as well as aftermarket and value-added ser-vices. Portable coordinate measuring machines from Hexagon Metrology are efficient measuring solutions for components of all sizes. Customers can benefit from enormous time and cost savings by simply being able to take the measuring system to where it’s needed. In the field of portable metrology, Hexagon Metrology offers the Romer Absolute Arm, the most

Hexagon Metrology Booth # B28/B29

precise Romer coordinate measuring machine. The new Romer measuring arm, the first to be equipped with abso-lute encoders, greatly simplifies the process of measuring. With this tech-nology, there is no need to initialize all the encoders, as was previously the case with every measuring arm—the user simply switches the measuring machine on and starts to measure.

For more information:Hexagon Metrology Services Ltd.Cedar House78 Portsmouth RoadCobham, SurreyKT11 1AN United KingdomPhone: +(44) 20 7068 6580www.hexagonmetrology.com

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Gleason Corporation will introduce a host of advanced new capabilities, tech-nologies and localized customer support services at IPTEX 2012 for the complete production and inspection of all types of cylindrical and bevel gears. Among the most significant of these are:

G e n e s i s p r o d u c t i o n c a p a -bilities. Gleason Works (India) in Bangalore now gives Gleason’s cus-tomers in India faster, more efficient access to advanced cylindrical gear production technology with local pro-duction of Gleason’s Genesis hobbing machines.

Opti-Grind, delivering up to a 40 percent increase in productivity. Significant productivity benefits are possible on new Gleason profile grind-ing machines utilizing the Opti-Grind process. This technology uses mul-tiple grinding wheels (for roughing and finishing), achieving significantly reduced production times. In addition to the productivity gains inherent in the use of Opti-Grind, users also ben-efit from improved part quality as a consequence of optimized contact con-ditions between the grinding wheel and the workpiece flank and improved surface finish.

A complete line of gear cutting tools and workholding solutions. Gleason supplies every cutting tool for the production of cylindrical and bevel gears of all types and sizes. For the production of large cylindri-cal gears, Gleason offers the Opti-Cut family, which provides users with all the performance benefits of the latest replaceable, indexable, carbide insert technology. Opti-Cut can reduce cost-per-part by as much as 50 percent as compared to conventional high speed steel cutters. The family is versatile too, including gear gashing, hobbing and shaping products in a variety of

Gleason Booth # D1A

cutter body sizes, insert types and geometries to meet a wide range of roughing and finishing, and internal and external gear production require-ments. Gleason offers coarse pitch hobs for large cylindrical gears, with the shortest lead times in the industry.

Advanced workholding solu-tions. In addition, Gleason designs and produces a complete series of quick-change, tool-less workholding equipment for both cylindrical gear and bevel gear, and non-gear produc-tion machines. These systems range from Gleason X-Pandisk systems, which automatically align workpiec-es weighing up to 2,000 kg to reduce changeover time by up to 70 percent, to Quik-Flex and a large variety of quick-change workholding solutions that significantly reduce change-over times for the production of both bevel and cylindrical gears.

Localized service and sup-port. With operations in Bangalore, Mumbai, Delhi, Coimbatore, Pune and Chennai, Gleason Works (India) enables its customers anywhere in India to take full advantage of a com-plete array of service and support capabilities, including: support, service parts, training, equipment upgrades, application development and cutting tool manufacture and refurbishment.

For more information:Gleason Works (India) Private Limited Plot No. 37, Doddenakundi Industrial Area, Whitefield Road, Mahadevapura, Bangalore 560 048Phone: + (91)80 28524315www.gleason.com

Gleason offers a complete line of gear cutting tools and workholding solutions for all types and sizes of bevel and cylindrical gears (courtesy of Gleason).

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Klingelnberg/Liebherr Booth # B14

P 26 by Klingelnberg. Klingelnberg will exhibit the gear measuring center P 26 at IPTEX. This fully automatic CNC controlled machine has been designed as a compact unit for the smaller work-piece diameter range up to 260 mm. P 26 is suitable for testing spur and heli-cal gears as well as hobs, shaper and shaving cutters, worms and wormgears, bevel gears and general deviations. Also, the machine provides precise size, form and position measurement of axi-ally symmetrical objects.

In addition to the mechanical com-ponents such as bed, workpiece rota-tion, the tailstock, the horizontal, verti-cal and tangential measuring axis and the 3-D tracer head, a 4-axis path con-trol in conjunction with a computer ensures the functions of this machine.

Preparatory works for carrying out a measurement are extremely simple with this machine concept. The quick and easy testing in combination with extensive software solutions for evalu-ating the measuring results contrib-ute to reliable and efficient production processes. Industries include automo-tive, aviation, precision engineering, industrial construction and plant engi-neering; maximum outside diameter of gear is 260 mm, max. test gear weight up to 80 kg, max., vertical measur-ing width 400 mm, gear measurement as well as size, form and position measurement of axially symmetrical objects of all types. Versatile options for testing automotive drive elements, clutch gears, sprockets, beveloid gears as well as camshafts and crankshafts are available.

Modular gear hobbing machine LC 180 by Liebherr. Liebherr will present the LC 180 from the Platform 1 segment. The respective production series LC 80 to LC 180 gear hobbing machines have a compact design and

distinguish themselves with their inter-nal machine bed circulation, providing a special thermic stability. Workpiece changes are done within two seconds. For NC control, different options are available. For small gears up to mod-ule 2, a directly powered cutter head featuring a max. 9,000 1/min can be employed.

Liebherr’s gear hobbing machine program contains a full production series of up to 6,000 mm workpiece diameter. For the automotive indus-try, the HSC-dry cutting technology increases productivity by 30 percent and makes coolant use redundant. The gear hobbing machines represent a uni-versal platform for shaping machines and for generating and profile grinding technology. The gear hobbing machine program is based on a modular con-cept with four different size segments (Platform 1: 180 mm, Platform 2: 380

mm, Platform 3: 1,600 mm, Platform 4: 6,000 mm).

For more information:Klingelnberg GmbHPeterstrasse 45D-42499 HückeswagenPhone: + (49) 2192 810Fax: + (49) 2192 [email protected]

Liebherr-International Deutschland GmbHHans-Liebherr-Strasse 45 D-88400 Biberach an der RissPhone: + (49) 7351 41-0 Fax: + (49) 7351 41-2650 [email protected]

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Dontyne software and consultan-cy services are aimed at the efficient design and manufacture of geared sys-tems and their use in the transmission industry. In the five years since forma-tion the company has enjoyed rapid growth with nearly 100 customers in 15 countries. The main markets are U.K., Europe, United States and Japan. The customer base is broad covering automotive and motor sport, marine, mining and military applications. The support is from main offices in U.K. and Australia, with various sales and technical support around the world. India represents a new and exciting market and there is already suitable support in place. The company has enjoyed success due to the rapid devel-opment time enabled by the software products. Together with the modular construction it is versatile enough to be utilized by companies with exist-ing design tools or in-house develop-ment. Dontyne offers training on gear design theory as well as bespoke work, including integration to in-house soft-ware.

The Gear Production Suite is a col-lection of software tools which form a powerful product development sys-tem with common access from differ-ent departments (design, manufacture, inspection) on one or multiple sites for efficient management of project data. Tools can be used to carry out design and manufacture optimization, gear inspection, failure analysis or product development. Improved communica-tion enables rapid analysis and reduced lead times resulting in considerable efficiency savings and better quality control.

“We have had a really good year extending our customer base great-ly worldwide,” says Dontyne’s Mike Fish. “We have recently moved into

Dontyne Systems Booth # A25

new offices in Newcastle city center to support the growth. Following the success of the Gear Expo in Cincinnati it was very opportune to be able to fol-low it with an exhibition like IPTEX 2012 so soon after. The feedback from the visitors to the stand was that the easy-to-use GUI and low cost made our software very desirable. The reduced time to develop and optimize design for performance was especially noticed by the attendees.

Of special note though were the machine simulations and links to metrology equipment. This is of partic-ular interest to those involved in manu-facture, and this is why we are confi-dent that many companies in India will be able to utilize our software to great effect. We produce machine simula-tion of spur and helical manufacture, whether by hob, grind (and dressing), shaped, shaved, wire erosion or injec-tion mold. We also look at worm gear manufacture thread grinding and hob-bing of the wheel.”

Additionally, Dontyne is develop-ing techniques to look at bevel man-ufacture as bevel gears will be new for the 5.0 version in February. “The ‘Connections’ functionality has been extended from just spline to offer shaft and bearing design tools. Following the implementation of Micropitting ISO TR 15144 Method A and B for Release 4.6 in October, we have implemented a technique for the new release developed by Dave Barnett to predict the behavior of micropitting erosion well beyond the period defined in the ISO. This is linked to our tooth contact analysis model such that the long term effects on operating charac-teristics can be properly assessed.”

For more information:Dontyne SystemsRotterdam House116 QuaysideNewcastle Upon TyneEngland NE1 3DY Phone: + (44) 191 206 4021 [email protected]

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MGM brake motors are asynchro-nous three-phase totally enclosed fan cooled motors.

The motor brakes in the event of a power supply failure. The braking action is always obtained through a very quick and precise stop, thereby guaranteeing a safe and prompt inter-vention in the event of an unforeseen power supply failure. The braking action is obtained without shaft axial sliding and it provides equal braking torque in both directions of rotation. MGM brake motors are particular-ly suitable for hoisting and traverse applications, tooling machinery, auto-matic and transfer machinery in tex-tile, ceramic and packing fields and in

MGM-Varvel Power Transmission Booth # C7

Bonfi glioli Transmissions Pvt. Limited Booth #P1

Bonfiglioli Riduttori is a global sup-plier of geared motors, gearboxes, elec-tric motors and drives for various indus-trial applications. In 1999, Bonfiglioli Transmissions Pvt. Limited was started in India offering power transmission products from various industry seg-ments like construction, earth-moving, mining, steel, cement, sugar mills, agricultural and farm equipment, food, power plant, material handling, tex-tile, packaging and alternative energy. The company has a wide sales network spread all over the country supported by a dealer network to address customers pre- and after- sales service needs.

“After establishing a niche in worm and helical geared motors, Bonfiglioli has now launched a heavy duty range of geared motors and gear units in helical/bevel helical and planetary configuration for the Indian market. These units have very high power-to- weight transmit-ting capacity combined with modularity and superior finish over the contempo-rary products available in India,” says N. Rajan, head of marketing and sales.

Bonfiglioli also has a complete range of energy efficient electric motors that are designed standard to accommodate VFDs. Bonfiglioli’s new “Agile” range of sensor-less vec-tor VFDs manufactured in Germany are now available in India. They are easy to install and program without the need for specialized resources. Apart from the above Bonfiglioli also

every situation where precision and quickness in braking are required. MGM brake motors are designed and assembled as real brake motors. The engineering and assembling, com-bined with a strong and safe brake, make these motors very reliable. As standard on the IM B3 mounting (foot mounted), the feet are integrated in the frame (they are not simply attached to the frame), making the motor very sturdy. This feature is very important on those brake motor applications where the stress during start/stop is very high. The brake disc lining mate-rial is asbestos free with a high friction coefficient and is very long-lasting. Motors are provided with IP54 enclo-sure rating and insulation class F. On request, IP55 or IP56 enclosure ratings and class H insulation can be provided. All MGM motors are designed for use with an inverter. It is also possible to

supply the motor with the encoder fit-ted on the second shaft end or to have the second shaft end ready to be fitted with an encoder.

Additionally, modularity and flex-ibility have been leading the design of Varvel gearbox products since 2000. Products include parallel shaft, shaft mounted, bevel/helical gearboxes, worm speed reducers, helical speed reducers and planetary speed reducers.

For more information:MGM-Varvel Power TransmissionDoor No. 68 - Indus Valley’s Logistic Park Unit 3 - Mel Ayanambakkam - Vellala StreetChennai - 600 095 - Tamil Nadu – IndiaPhone: + (91) 44 64627008 www.mgmvarvelindia.com

manufactures and markets a range of low backlash planetary gear units and performance servomotors for special applications.

For more information:Bonfiglioli Transmission (Pvt) LtdSurvey No.528, Perambakkam High Road, Sriperumbudur, T.Nadu-602105. IndiaPhone : + (91)[email protected]

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Q & A

Mr. Prasad, please give us a short introduction to GearPro.

GearPro is a modular software solution which enables its owner to cut cylindrical and bevel gears on MAG turning and milling centers equipped with the latest five-axis technology. The results are qualities which are equal to those that can be achieved with state-of-the-art dedicated gear manufacturing methods.

Can you describe how GearPro works?

The main requirement for the suc-cessful functioning of GearPro is the rigid design of the machine itself and the highly precise interaction of all moving components, which influence the final quality directly or indirectly.

Especially important for the deter-mination of quality is the work table or work spindle. If the main spindle is not well synchronized with the milling spindle, it is impossible to realize good quality. In our current machine tools this is achieved with the integration of a pre-loaded tandem drive, which can be

At EMO 2011 in Hannover, MAG introduced the new GearPro Universal Gear Milling software on its turning and milling centers. Eswari Prasad, president of MAG India, explains the strategy behind these new products and the advan-tages of the new solution.

steplessly adjusted.Finally, a five-axis milling head is

required. MAG turn/mill heads are spe-cifically optimized for milling applica-tions and serve the compromise between torque and speed to achieve the high-est removal rates during roughing and maximum precision for finishing at high speeds.

Regarding the mode of operation, GearPro itself is based on a machine-specific post processor, which calls on various modules in a universal software construction set. With this tool our cus-tomers can choose only the modules they actually require for the specific application without purchasing ele-ments they may never require.

Extensions would be possible at any time?

Further functionalities or modules can be added at any time, as long as the previ-ously mentioned components are avail-able and the basic GearPro package is installed on the machine in question. But also the complete GearPro package can be installed at a later point in time.

There is a range of software options for gear cutting with end mill cutters already available. What’s so special about your product?

Quite simply, it’s the quality and the application range. Today we are the only manufacturer who is not just able to offer the machining of regular straight and helical bevel gears but a variety of brand-specific gears, all at high-level quality. Among these designs are Gleason and Klingelnberg gears, (Palloid, Cyclo-Palloid and hypoid gears), MAG Modul-Curvex Designs, Oerlikon-Spiromatic gears as well as special S-type gears.

Naturally our program covers the complete range of cylindrical gearings, including internal gears. The latter are limited by the interaction between inter-nal gear diameter and the size of the milling head with its attached end mill.

Furthermore we do not leave our customers alone with their gear manu-facturing problems. Together with our partner HPG we offer additional serv-ices including the calculation of gears, the optimization of bevel gear flank con-tact patterns and the measurement of gears within the machine and linked to external measuring machines. MAG and our customers prosper from the extensive gear knowhow of MAG Modul in Chemnitz and our Partner HPG Nederland.

What class of quality can your customers achieve with your option?

The quality improvements compared to traditional processes are enabled by the multitasking machining process which allows us to turn, mill and cut the gear on one spindle with a maximum of two clampings. Quality loss caused by re-clamping is practically eliminated. On the other hand, great quality can be achieved by finishing the hardened gear

GearPro Software EXTENDS TURNING AND MILLING MACHINES

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with a very low feed rate where each pass is able to machine down to the smallest tolerance.

If you are experienced in the field of gear manufacturing, you obvious-ly know the different gear classifica-tions around the globe like DIN, AGMA (3-15) or the Japanese JIS. For those who are thinking about starting to pro-duce their own gears, I would just like to give an idea of the system. While the European DIN standard differentiates 12 quality classes with quality 1 repre-senting the perfect gear, the American AGMA standard shows classes from 3 to 12 with 12 being the best possible result.

GearPro is based on a theoretically perfect model where a quality 1 gear is produced under optimum conditions. Naturally any deviations from this per-fect world, like inhomogeneous materi-als, temperature deviations, tool wear and any kind of vibrations during the cutting process, result in deteriorations from the optimum result, so that in prac-tice our customers can realize qualities up to DIN 3 or AGMA 10.

As a rule we realize standard quali-ties required in daily gear produc-tion like DIN 5 or 6 without problems. Quality is possible with good setup and process control. Users can also prede-fine a certain quality level in the soft-ware to produce fast and problem-free to the required tolerances.

Thinking about an ordinary sit-uation in typical workday life, how much know-how in gear technology is required to operate with GearPro?

Our GearPro system can be used without special gear knowhow and ena-bles also inexperienced users to achieve excellent results. If all relevant gear data is available and entered into the easy-to-use MAG user interface, the software guides the operator subse-quently through the single process steps. Based on this input, GearPro generates the CNC machine code.

What kind of tools do you use, and when do you use them?

We use standard end mills for the gear milling. Customers who previously had to wait for weeks or months for the supply of special gear tools can now rely on the immediate availability of off-the-shelf tooling and tools to start their production right away—with tool

costs per workpiece which can be exact-ly determined.

GearPro determines the various, required tool types and the ideal time of tool change. Operators can override these recommendations if they want to adjust features or they want to use a certain end mill type they have in stock. Naturally, our machines are fitted with standard tool holders and adapters of our customers’ choice such as HSK 60, HSK 80 or the Capto system.

What do customers have to invest to operate with GearPro and end mills compared to the conventional gear manufacturing systems?

This depends on the customers’ requirements. Generally speaking, the wider the gear application range they want to cover, the more software mod-ules they will require.

Principally we do have very good news for gear manufacturers of small and medium gear lots. Until now, in order to produce a gear of DIN qual-ity 5, you had to invest in one turning/drilling center, one gear hobbing/mill-ing machine and one gear grinding machine. With the installation of our GearPro software in combination with a high-precision MAG turning or milling center with five-axis milling technology, this huge investment can be cut down to only 40 percent of the former total volume, not even counting cost factors such as space requirements and cost of power which is reduced to one third.

Cutting gears with end mills is worthwhile, especially for prototype manufacturing, repair work, small and

medium batches and very large gears. Especially with regard to large gears, the eliminated workpiece handling between different machines shows the most positive effect on productivity.

What machine tool models can be equipped with GearPro?

We offer our customer currently two proven products for the complete manu-facturing of gears. The VDM 1000 TM where vertical workpiece axis is suited for pinions, rings, wheels and shafts. The VDF 450 TM has been designed for efficient manufacturing of long shaft-type workpieces. The abbreviation TM stands for the turn-mill function with five-axis milling heads. Furthermore our milling centers of the NBH and NBV series are equipped with GearPro.

For more information:MAG India IAS Pvt. Ltd.#67, 1st Main, Industrial Suburb2nd Stage, YeshwantpurBangalore 560 022Phone: +(91) 80-4067-7000Fax: +(91) 80-4160-0777www.mag-ias.com

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Shanthi Gears Ltd. (SGL) has long been a darling of the investment community. With dividend rates around 100 per-cent, average annual growth of around 20 percent and the notoriety that comes with being featured in Forbes magazine (“Best Under a Billion, 2004”) and advertising in Newsweek, it’s no surprise why.

But with notoriety comes notice, and India’s manufactur-ing sector is no longer a secret. In recent years, many foreign competitors have come into the market, particularly the major European gearbox manufacturers.

Despite these challenges, Shanthi Gears has worked to position itself not only to survive, but to continue growing at the pace to which its investors have become accustomed.

One of the biggest recent changes was a restructuring of the company’s management. In May 2011, the company hired V.C.S. Velumani as its CEO. Previously, Velumani had been executive director of Winergy Drive Systems India Pvt. Ltd., a major manufacturer of wind turbine gearboxes. This was a big step for Shanthi Gears, which had been previously run and managed on a day-to-day basis by P. Subramanian, the original entrepreneur who founded the company as Shanthi Engineering & Trading Co. in 1969.

In a press release distributed at the time of Velumani’s hire, Subramanian described the move as “a milestone” for the company. Although Subramanian remains chairman and managing director, he and the other directors felt that new leadership would help the company compete in the future. Velumani, who helped set up Winergy’s Chennai factory, seemed the right man for the job.

“My experience at Winergy helped me to learn the impor-

ShanthiGears

FROM CUSTOM GEARBOXES TO STANDARD

DRIVES, SERVING INDIA AND THE WORLD

By William R. Stott, Managing Editor Shanthi Gears believes in investing in the latest technology for gear manufacturing. Here is shown a helical gear being profile ground after harden-ing on a CNC gear grinding machine imported from Germany (all photos courtesy Shanthi Gears).

Shanthi Gears has a wide variety of manu-facturing equipment, allowing it to make any type of gear.

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continued

tance of technology and efficiency, which will be a driving point at SGL,” Velumani says.

One of Velumani’s biggest goals will be to help shift the focus of Shanthi Gears from its heavy concentration on custom, non-standard gearboxes, toward an emphasis on the standard gearboxes that are currently higher in demand.

“The market is moving towards standard products because of cost as well as deliveries,” Velumani says. “Hence at SGL we also want to concentrate on standard products, though we continue to handle non-standard gearboxes, too.”

The shift in philosophy has required the company to invest in personnel and R&D. According to Velumani, Shanthi Gears’ R&D department employs a number of European-educated and trained experts who are helping the company increase the quality of its standard product line, as well as the number and types of standard gearboxes available.

“In two years’ time, SGL will be in a position to manufac-ture any kind of gearboxes,” Velumani says, adding that this will help them compete and regain market share from many of the foreign competitors who have entered the marketplace.

Shanthi Gears from Yesterday to TodayShanthi Gears opened its doors in 1969 as Shanthi

Engineering & Trading Co. The company first started making gears for textile machinery by the simple process of milling. But by 1972, when the company changed its name to Shanthi Gear Products (P) Ltd., they had started to produce all types of gears for a wide variety of industries.

Today, Shanthi Gears is one of the largest manufacturers of loose gearing in India, with more than 300,000 gear wheels and accessories produced in the fiscal year ending in March 2011, at a value of nearly 600 million rupees. But the greater share of the business comes from enclosed gearboxes, which accounted for more than 900 million rupees in sales for the same period.

Although the majority of its gearbox sales continue to be from custom, non-standard gearboxes, the shift in corporate philosophy and emphasis should provide significant growth in the area of standard gearboxes for many years to come.

The company owns five factories, including its own dedi-cated forging and casting facility, as well as its own in-house heat treating, making Shanthi Gears one of the few suppliers with control over the complete supply chain for making its products. Shanthi Gears is capable of producing centrifugal castings of phosphor bronze rings, ferrous castings, aluminum castings, forgings and fabrications. The company also has the capability to produce its own cutting tools.

“The biggest advantage of having every facility in-house,” says Velumani, “is that customers are assured of international quality and the quickest delivery at Indian prices.”

The company even generates its own power, through the use of nine wind turbines operating on its facilities for a total capacity of 6,660 kW.

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Tool Masters is the leading manufacturer of a wide range of precision Gear Tools like Gear Hobs, Shaper and Shaving Cutters, Broaches and Special Form Cutters. Our product quality is well supported by “State-of-the-art” machines for manufacture with a strict in-process control. High quality raw material, the best heat treatments and coatings along with personnel experience have always enabled us to meet customers’ require-ments.

Tool Masters India “Cutting Tool Specialists” 29, Industrial Estate • Patiala-147004 INDIA Ph: +91-9876300890 • Fax: + 91-175-5001405 www.tool-masters.com • e-mail: [email protected]

ENGINEERED FOR PRECISION

ISO 9001:2008 Company

One of Shanthi Gears specialties is the manufacture of cus-tom gearboxes. Here is shown a 2-high pinion stand gear-box used in steel rolling mills. Its centre distance is 1,180 mm and its weight is 10 tonnes.

Shanthi Gears caters to almost all industries except auto-motive. Of particular note are steel (15 percent of sales), power generation (15 percent), cement (10 percent), bulk material handling (10 percent), textile (10 percent), plastic (5 percent), sugar refining (5 percent) and mining (5 percent).

Although the majority of its sales are to the Indian mar-ket, Shanthi Gears views itself as a global manufacturer, with world-class facilities and a continual emphasis on quality. Its AS 9100C (based on and including ISO 9001:2008) certifica-tion, along with its ability to manufacture to standards such as AS9100B and AS9100C, allow the company to sell globally. Approximately 12 percent of sales are through exports to Canada, Thailand, USA, Indonesia and the Arab countries.

The proof of their quality is that a good portion of those export sales are loose gears sold to foreign competitors, Velumani says.

For more information:Shanthi Gears Limited304-A, Shanthi Gears RoadSinganallur, Coimbatore - 641 005Tamil Nadu, IndiaTelephone : + 91 422 2273722 - 34Fax : +91 422 2273884 & [email protected]

We reduce the friction

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Best People • Best Products • Best Value175 Ogden Road, Mantua, NJ 08051 USA

800-433-LUBE • 856-468-0216 Fax: 856-468-0200 • www.hangsterfers.com

An ISO 9001:2008 Company

The Clear Choicefor the Gear Component Industry

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and feeds• Reduces cycle time

Distributed by:SUPRA INDUSTRIESSP 106 MIDC BHOSARI S -BLOCK.PUNE 411026. INDIAtel no : + 91 20 30685648fax no: + 91 20 [email protected]

Hang Generic Gear Supra_Layout 3 1/3/12 10:49 AM Page 1

I

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hen designing gears, the size, weight and man-ufacturing cost can be influenced to a great extent by both strategi-

cally splitting the overall reduction over the individual stages and by optimizing the geometric relationships. A newly developed tool, the KISSsoft Gearing Variant Generator is able to automati-cally generate different gear variants, all of which have the same total reduc-tion and performance but have different numbers of stages and distribution of reduction across their stages. In addi-tion, the generator systematically var-ies design parameters that are known to have a fundamental influence on gear size. These different drive vari-ants are all sized exactly with gears, shafts and bearings that suit the torque to be transferred. Each of these dif-ferent solutions is numbered sequen-tially and displayed as a 3-D diagram to make the best solutions easy to identify. Two case studies that used the Gearing Variant Generator to analyze and opti-mize gears are detailed in this article. Both cases involve gear units used in the mining industry: one with 12 MW

W

Optimization With KISSsoft’s

Gearing Variant Generator

Dr. Ing. U. Kissling, KISSsoft AG, Hombrechtikon, Switzerland

Figure 1—Drive configuration.

nominal power and the second with 200 kW nominal power. The study revealed the weight and cost saving potential for both.

Surface Mining Gear Units from U.S. Manufacturer

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

In this analysis, only one drive-train—consisting of one motor with input and output stages—will be considered. There is no real point in modifying the variant generator to the effective, less common drive configu-ration because it’s possible to correctly reproduce the influence of the other

motors in the calculation without any additional effort. Because the output gear on the input stage drives two pinions, it is simply a case of doubling the number of load cycles of the output gear. Furthermore—as the output stage pinion transfers double the amount of power—the application factor of the output stage, KA, is also doubled. Finally, to take the different numbers of individual parts into consideration when calculating the total weight and the manufacturing cost, the specific weight is also doubled or quadrupled accordingly. With these modifications, the existing four motor drive design can be represented as accurately and realistically as possible.

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

The results of the analysis of the actual situation are given in Table 1. Here the weight was calculated using the same method as was used later to cal-culate the variants. The manufacturing costs shown here were each determined as $/kg prices using data provided by the manufacturer. This examination takes into account the cost for shafts, pinion shafts, gears and housing. The cost for the roller bearings has been omitted because bearings of this size are not commonly available and no standard prices could be found for them.

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

Input stage Output stage Gear unit

Torque 4 * 20.5 kNm 2,914 kNm 6.35 MWSpeed 730 rpm 20.76 rpmReduction i 9.40 3.78 35.53Safety Root SF 3.13 3.19 >= 3.13Safety Flank SH 1.01 1.41 >= 1.01Center distance a 1,320.8 mm 2,489.2 mmFacewidth b* 394 mm 594 mmb/a 0.30 0.24

continued

As requested by the customer, the variant analysis was performed with only two stages, although for an overall reduction of 35.5, a three stage variant would be well worth considering. The input stage reduction was varied in 10 steps: from 5.00 to 13.16 (and the drive correspondingly from 7.09 to 2.70). In addition, the program counted upwards from 0.15 to 0.40 in increments of 0.05 for each ratio variant. As a result, it cal-culated a total of 70 gear units.

Figure 2 shows the gear housing dimensions of the different variants. They vary greatly in length, from 5,300 to 7,500 mm on the X axis, and from 1,030 to 2,100 mm on the Y axis, and from 3,280 to 5,600 mm on the Z axis. Of even greater interest is the overall weight and manufacturing costs shown in Figure 3. The least heavy variants are those with i2 = 5.1 and with b/a = 0.3. Those with the lowest manufacturing costs have i2 = 4.6 with b/a = 0.25. The figure clearly illustrates that cost as a function of i2 and b/a shows a fairly flat minimum that varies within the range i2 = 4.1 to 5.2 and b/a = 0.23 to 0.32.

Comparing the least expensive vari-ant (Table 2) with the status quo shows that costs could be reduced by 22 per-cent. Furthermore, the existing variant has a reduction distribution (i2 = 3.8), which lies below the optimum range, whereas the b/a values lie within the optimum range. In contrast, the existing variant does not have the best possible distribution of gear safeties. The output stage displays significantly higher safe-ties than the drive stages. This analysis shows that the current gear unit has been very well designed. When consid-ering the cost differences between the individual variants (Fig. 3) the actual cost still lies within reasonable bounds.

Table 2—Most important results for the optimum variant

Input stage Output stage Gear unitComparison

with ACTUAL

Reduction i 7.70 4.61 35.53

Safety Root SF 3.13 3.13 >= 3.13Safety Flank SH 1.01 1.01 >= 1.01

Center distance a 1,296 mm 2,222 mm

Facewidth b 325 mm 555 mm

b/a 0.25 0.25Housing length X (approx.) 5,900 mm - 2.6%

Roller bearing service life >= 68,000 h

Weight (approx.) 116,000 kg - 20.0%

Manufacturing costs (approx.) $367,000 - 22.1%

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

Input stage Output stage Gear unit Comparison

with ACTUALReduction i 9.40 3.61 35.53

Safety Root SF 3.20 3.23 >= 3.13

Safety Flank SH 1.03 1.02 >= 1.01

Center distance a 1,355 mm 2,048 mm

Facewidth b 271 mm 409 mm

b/a 0.20 0.20

Housing length X (approx.) 5,565 mm - 8.2%

Roller bearing service life

>= 68,000 h

Weight (approx.) 73,000 kg - 49.6%

Manufacturing costs (approx.) $294,000 - 37.5%Figure 2—Housing dimensions (X, Y, Z)

of the different variants.

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analysis were estimated approximately and would need to be defined in more detail.

Mining Gear Units from a German ManufacturerThe second case study involves a

medium-sized gear unit (200 kW) man-ufactured by Bucyrus Europe GmbH for use in the mining industry and with a traditional European industrial gear-box design. All the gears are made of case-hardened steel and the drive stage is ground.

The procedure for the analysis was carried out as shown in the example: The results of the analysis of the actual situation (where the variant was cal-culated with two stages) are shown in Table 4. The reduction of the drive stage was varied in nine steps—from 1.20 to 3.4 (and the drive correspond-ingly from 6.00 to 2.2). In addition, b/a was varied from 0.10 to 0.90 in incre-ments of 0.20 for each ratio variant. A total of 45 gear units were calculated. Manufacturing costs were defined using EUR/kg pricing data provided by the manufacturer.

The results of the optimization process are shown in the figures that follow. It is obvious that there were significant differences in the external dimensions (Fig. 4). This result from the Gearing Variant Generator can be extremely useful if the new gear has to be installed in a specific space. The total weight and manufacturing costs displayed depending on b/a and i2 (Fig. 5) also clearly illustrates that this design example—where the output stage is not ground—gives the optimum drive variants for b/a = 0.3. The optimum b/a ratio is relatively small because, due to the non-ground output stage, the face load factor KHß would increase signifi-cantly as the width increases and would therefore make this variant cost-inten-sive. The ratio distribution between the stages gives good results if the output stage has a reduction in the range 2.0 to 3.0.

A second calculation run was per-formed to analyze the optimum range of solutions in greater detail; i.e., the reduction of the drive stage was varied in five steps—from 1.81 to 3.0 (and the drive correspondingly from 4.11 to 2.48). In this instance, b/a was increased for each ratio variant from 0.18 to 0.42,

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

Gearing Produced with Hardened Materials

It is well worth investigating wheth-er a more cost effective solution could be achieved by using surface hard-ened materials. This would possibly involve the practical option of manu-facturing the pinion shafts from case-hardened, ground steel, and the gears from heat treated (milled and nitrided) steel. The Gearing Variant Generator can perform this type of analysis very

Figure 4—Housing dimensions (X, Y, Z) of the different variants.

Figure 3—Weight and manufacturing costs depending on output stage reduction (i2) and the width/center distance ratio (b/a).

Figure 5—Weight and manufacturing cost (EUR) depending on the reduction of the output stage (i2) and of the width/center distance (b/a) ratio.

quickly once the manufacturing costs are known. As a rough starting point for this analysis, KISSsoft increased the cost for the pinion shafts (ground) by 100 percent and those for the gears (nitrided) by 50 percent.

For experts, the results bring no sur-prises: in this variant, the weight of the gear unit can be reduced by 50 percent. According to the cost calculation, the result is a reduction of 37.5—or 20 per-cent in the case of the optimized gear unit made of heat treated steel (Table 2). In this context it should be noted that the assumed cost rates for this last

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I

Table 4—Most important results of the analysis of the actual situation

Input stage Output stage Gear unitTorque 2.77 kNm 20.7 kNm 200 kWSpeed 662 rpm 88.6 rpmReduction i 1.90 3.93 7.47Safety Root SF 3.76 4.04 >= 3.76Safety Flank SH 1.74 1.42 >= 1.42Center distance a 307 mm 378 mmFacewidth b 95 mm 180 mmb/a 0.31 0.48Housing length X (approx.) 1,060 mm

Roller bearing service life >= 68,500 h

Weight (approx.) 1,400 kgManufacturing costs (approx.) EUR 23,000

Figure 6—Weight and manufacturing cost (EUR) after more detailed breakdown of the reduction interval and the b/a interval.

Table 5—Most important results for the optimum variantInput stage Output stage Gear unit Comparison

with ACTUALReduction i 2.05 3.60 7.47Safety Root SF 4.26 3.88 >= 3.76Safety Flank SH 1.42 1.44 >= 1.42Center distance a 276.2 mm 441.0 mmFacewidth b 71.8 mm 114.0 mmb/a 0.26 0.26Housing length X (approx.) 1,259 mm + 16%

Roller bearing service life >= 68,500 h

Weight (approx.) 1,073 kg - 23 %Manufacturing costs (approx.)

EUR 18,302 - 20 %

in increments of 0.04. This analysis calculated a total of 35 gear units whose results are shown in Figure 6.

Contrary to expectations, the second run did not find a significantly better solution. The best solution with regard to weight was found in the first calcu-lation run at b/a = 0.3 and i2 = 3.64, which gave a weight of 1,077 kg. In the second run, the optimum weight at b/a = 0.26 and i2 = 2.82 was 1,073 kg. The differences in manufacturing costs were also not very great. In the second run they were only reduced from EUR 18,360 to EUR 18,302—a reduction of only 0.3 percent. The range that contains drive variants with minimum costs is obviously scarcely affected by smaller changes to the output reduction or the b/a ratio. This situation is also very obvious in Figure 4. It is beneficial to recognize this fact, which can then be applied if it is intended to create differ-ent reduction systems in the same gear housing while keeping costs down.

Comparing the least expensive vari-ant (Table 5) with the status quo shows that costs could be reduced by 20 per-cent. The actual variant has a reduction distribution which almost lies in the optimum range, whereas the b/a values lie a little above it. KISSsoft believes the current gear unit has been fairly very well designed, even if a possible saving of 20 percent could be achieved, and should therefore be taken into con-sideration.

ConclusionTwo very different gear unit vari-

ants from mining applications were investigated with the Gearing Variant Generator. In both cases an analysis of the status quo was performed to deter-mine the effective strength values and safety factors for the gear units. Then, a large number of gear units, with the same strength values but with differ-ing reduction distribution due to dif-ferent stages and b/a parameter, were designed.

In both cases the study showed that the gear units were definitely well designed for their intended purpose. Compared to the range of possible solutions, the current actual design lies in the “green” zone. Nevertheless, the study showed that, in both cases, costs could be reduced by 20 percent if the best possible solution were adopted.

In both cases, KISSsoft’s Gearing Variant Generator has proved its effec-tiveness; without this tool it would have been impossible to perform these studies so quickly, even with the most sophisticated software.

References1. Kissling, U. Optimierungsprozedur zum Auslegen von Stirnradgetrieben nach Gewicht, Kosten und Wirkungsgrad, Zeitschrift‚ Konstruktion, 2011, Heft 3.2. Kissling, U. and R. Kivelä. “Automatic Optimization Procedure of a Complete Gearbox for Weight, Efficiency, Costs and Dimensional Restrictions,” International Conference on Gears; VDI Bericht, 2108.2; 2010.

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With operations in Mumbai, Delhi, Chennai, Coimbatore and Pune, Gleason Sales (India) can help you get the most out of your Gleason Total Gear Solutions, with:

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For worldwide sales locations and additional information, visit: www.gleason.com, or [email protected]

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The World’s Most Productive The World’s Most Productive Gear Hobbing Machines...Gear Hobbing Machines...Now Built in India.Now Built in India.

INDIA IS ON THE MOVE…WITH TOTAL GEAR SOLUTIONS FROM GLEASON

We’re building the Genesis® series, the world’s most advanced gear hobbing machines, at our expanded facilities in Bangalore, giving customers in India faster, more efficient local access to the world’s best gear production technology.

Throughout India, Gleason technologies are at work, helping customers in transportation, energy, aerospace and many other industries produce gears of all types and sizes faster and more economically.

With operations in Mumbai, Delhi, Chennai, Coimbatore and Pune, Gleason Sales (India) can help you get the most out of your Gleason Total Gear Solutions, with:

Support

Training

Service Programs

Application Development

Equipment Upgrades

Cutting Tool Manufacture and Refurbishment

For worldwide sales locations and additional information, visit: www.gleason.com, or [email protected]

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IntroductionLarge-sized spiral bevel gears are

often used for power transmission/thermal power generation applications (pulverizing, etc.). Due to the increase of energy demand in the world, the demand for large-sized spiral bevel gears has increased accordingly and may continue so for some time. These gears are usually manufactured based on a cyclo-palloid system, which pro-

Manufacturing Method of Large-Sized

Spiral Bevel Gears

IN CYCLO-PALLOID SYSTEM USING MULTI-AXIS CONTROL

AND MULTI-TASKING MACHINE TOOL

K. Kawasaki, I. Tsuji, Y. Abe and H. Gunbara

Management SummaryThe large-sized spiral bevel gears in a Klingelnberg cyclo-palloid system are manufactured using multi-axis control

and a multi-tasking machine tool. This manufacturing method has its advantages, such as arbitrary modification of the tooth surface and machining of the part minus the tooth surface. The pitch circular diameter of the gear treated in this study is more than 1,000 mm (approx. 40"). For this study, we first calculated the numerical coordinates on the tooth sur-faces of the spiral bevel gears and then modeled the tooth profiles using a 3-D CAD system. We then manufactured the large-sized spiral bevel gears based on a CAM process using multi-axis control and multi-tasking machine tooling. After rough cutting, the workpiece was heat treated and finished by swarf cutting (Ed.’s note: The removal and cutting of metal in which the axis of the cutting tool is varied with respect to the part being machined) using a radius end mill. The real tooth surfaces were measured using a coordinate measuring machine and the tooth flank form errors were detected using the measured coordinates. Moreover, the gears were meshed with each other and the tooth contact patterns were investigated. As a result, the validity of this manufacturing method was confirmed.

duces equi-depth teeth, but can also be produced using a face hobbing system, which produces tapered teeth (Refs. 1–3). The spiral bevel gears in this sys-tem are usually generated by a contin-uous-cutting procedure using special gear generating machines. However, the availability of those generators for this use has declined recently, while production costs have not. Therefore, the demand for high-precsion machin-

ing of large-sized spiral bevel gears has grown.

This article discusses the manufac-ture of large-sized spiral bevel gears in the Klingelnberg cyclo-palloid sys-tem using multi-axis control and multi-tasking machine tooling. The mate-rial of the workpiece was 17CrNiMo06 and was machined using a coated car-bide end mill. As a result, the detect-ed tooth flank form errors were small.

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W(Xψ) between crown gear and gener-ated gear at the moment when generat-ing angle is ψ, the equation of meshing between the two gears is as follows (Refs. 8–9):

(4)

From Equation 4 we have θ = θ (v, ψ). Substituting θ (v, ψ) into Xψ and Nψ, any point on the tool surface of the crown gear and its unit normal are

continued

Moreover, the tooth contact patterns of the manufactured large-sized spiral bevel gears were observed and those positions were good.

Tooth Surfaces of Spiral Bevel Gears

The generator and cutter heads that Klingelnberg manufactures are typi-cally utilized in spiral bevel gear cut-ting in the cyclo-palloid system. The equi-depth teeth of the complemen-tary crown gear are produced one after another by the rotating and turning motions of the cutter in this method—i.e., the tooth trace of the complemen-tary crown gear is an extended epicy-cloid. Therefore, the spiral bevel gears in this system are generated by a con-tinuous cutting procedure.

Figure 1 shows the basic concept that produces an extended epicycloid. O-xyz is the coordinate system fixed to the crown gear and the z axis is the crown gear axis. O

c is the center of

both the rolling circle R and the cutter. The cutter fixed to the rolling circle R rotates under the situation. OO

c is

the machine distance and is denoted by M

d. When the rolling circle R of

radius r (Md–q) rolls on the base circle Q of radius q, the locus on the pitch surface described by the point P which is a point fixed to the circle R is an extended epicycloid. When the spiral bevel gear is generated for hard cutting on the special generator after heat treat-ment, a cutter with circular-arc cut-ting edges is used. These circular-arc cutting edges provide a profile modi-fication to the tooth surfaces of the generated gear. Therefore, a cutter with circular-arc cutting edges is considered in this article.

Figure 2 shows the cutter with cir-cular cutting edges. O

c-x

cy

cz

c is the

coordinate system fixed to the cutter. O

c is the cutter center; z

c is the cut-

ter axis; rc is the cutter radius; γ is the

pressure angle of the inner cutting edge of the cutter; ρ is the radius of the cur-vature of circular arc cutting edge; y

ci,

zci are the coordinates of the center of

curvature of circular arc in plane xc =

0, and are expressed as a function of γ and ρ (Ref. 7); θ is the parameter

which represents inner curved line. The inner cutting edge X

c is expressed on

plane ycz

c in Oc-x

cy

cz

c by the following

equation:

(1)

The surface of the locus described by X

c in O-xyz is expressed as:

(2)

where C is the coordinate transfor-mation matrix for the rotation about z axis:

(3)

In Equations 2 and 3, v is a param-eter which represents the rotation angle of the cutter about the z axis, and R

m

is the mean cone distance (Fig. 3). X expresses the equation of the tooth (tool) surface of the complementary crown gear. The unit normal of X is expressed by N.

The complementary crown gear is rotated about the z axis by angle ψ and generates the tooth surface of the spiral bevel gear. We call this rotation angle ψ of the crown gear the generat-ing angle. When the generating angle is ψ, X and N are rewritten as Xψ and Nψ in O-XYZ assuming that the coordinate system O-xyz is rotated about the z axis by ψ in the coordinate system O-XYZ fixed in space. When ψ is zero, O-XYZ coincides wit h O-xyz.

Assuming the relative velocity

z

Extended epicycloid

Q

O

x

yc

R

q

Fig. 1: Extended epicycloid

P

�rc

xc yc

zc

Cutter

(yci, zci)

Oc

Fig. 2: Cutting edges of cutter

z

Extended epicycloid

Q

O

x

yc

R

q

Fig. 1: Extended epicycloid

P

�rc

xc yc

zc

Cutter

(yci, zci)

Oc

Fig. 2: Cutting edges of cutter

Figure 1—Extended epicycloid.

Figure 2—Cutting edges of cutter.

yc

�0

Oc

� 0

O,zx

y

P

Extendedepicycloid

R

xc

Q

Fig. 3: Locus of cutting edge

Figure 3—Locus of cutting edge.

sincos

0)(

cci

ccic

rzr=X (1)

)()()(),( 1 DXCX c (2)

md

cmd

d

d

cm

dcm

d

RMrRM

MM

rRMrR

Θ

ΘrM

2cos

0)cos()sin(

)(

2cos

)(

1000cossin0sincos

)(

222

0

0

0

222

0

01

11

11

1

D

C

(3)

θzy

+-

θθ

θv = θ θ + v

θ =θθ

– θθ

θ v v=

=

+

–+

v =– θv –

θv –

θ =–+

0);,();,( WN (4) ψ θv ψ • θv ψ =

sincos

0)(

cci

ccic

rzr=X (1)

)()()(),( 1 DXCX c (2)

md

cmd

d

d

cm

dcm

d

RMrRM

MM

rRMrR

Θ

ΘrM

2cos

0)cos()sin(

)(

2cos

)(

1000cossin0sincos

)(

222

0

0

0

222

0

01

11

11

1

D

C

(3)

θzy

+-

θθ

θv = θ θ + v

θ =θθ

– θθ

θ v v=

=

+

–+

v =– θv –

θv –

θ =–+

0);,();,( WN (4) ψ θv ψ • θv ψ =

sincos

0)(

cci

ccic

rzr=X (1)

)()()(),( 1 DXCX c (2)

md

cmd

d

d

cm

dcm

d

RMrRM

MM

rRMrR

Θ

ΘrM

2cos

0)cos()sin(

)(

2cos

)(

1000cossin0sincos

)(

222

0

0

0

222

0

01

11

11

1

D

C

(3)

θzy

+-

θθ

θv = θ θ + v

θ =θθ

– θθ

θ v v=

=

+

–+

v =– θv –

θv –

θ =–+

0);,();,( WN (4) ψ θv ψ • θv ψ =

sincos

0)(

cci

ccic

rzr=X (1)

)()()(),( 1 DXCX c (2)

md

cmd

d

d

cm

dcm

d

RMrRM

MM

rRMrR

Θ

ΘrM

2cos

0)cos()sin(

)(

2cos

)(

1000cossin0sincos

)(

222

0

0

0

222

0

01

11

11

1

D

C

(3)

θzy

+-

θθ

θv = θ θ + v

θ =θθ

– θθ

θ v v=

=

+

–+

v =– θv –

θv –

θ =–+

0);,();,( WN (4) ψ θv ψ • θv ψ =

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spiral bevel gears. Table 2 shows the cutter specifications and machine set-tings in the calculation of the design; the PCD (pitch circle diameter) of the gear is 1,350 mm (approx. 53").

The determined coordinates are changed by the phase of one pitch after the tooth surfaces Xg Xg', Xp and Xp' are calculated. This process is repeated and produces the numerical coordinates on other convex and concave tooth sur-faces. When the range-of-existence of the workpiece that is composed of the root cone, face cone, heel and toe, etc., is indicated, the spiral bevel gear is modeled.

Figures 4 and 5 show the tooth profiles of the gear and pinion mod-eled using a 3-D CAD system based on the calculated numerical coordinates. The tool pass is calculated automati-cally after checking tool interferences, choosing a tool and indicating cutting conditions. In this way the CAM pro-cess is realized; when the numerical coordinates of the tooth surfaces are calculated, the tooth surfaces are esti-mated by the smoothing of a sequence of points, removal of the profile of undercutting, offset of tool radius and generation of NURBS (non-uniform rational basis-spline) surface (generat-ed from a series of curves). Moreover, by virtue of calculations of intersecting curved lines of convex and concave tooth surfaces—and sectional curved line—an approximation of straight line is conducted. This approach “escape” is added in order to avoid the interfer-ence. When the attitude of the tool and coordinate transformation is conduct-ed, NC data and IGES (initial graphics exchange specification) data for the machining and display are obtained.

Manufacturing of Large-Sized Spiral Bevel GearsThe gears were manufactured based

on CAD/CAM system mentioned above. The manufacturing processes were divided into three parts—rough-ing, semi-finishing and finishing machining.

Manufacturing of gear. The gear was machined by a ball end mill uti-lizing a vertical, three-axis machin-ing center. However, the gear could

defined by a combination of (v, ψ), respectively (Ed.’s note: Or normal vector—the normal to a surface is a vector perpendicular to it. The normal unit vector is often desired, sometimes known as the “unit normal.”). When the tool surface of the complementary crown gear in O-XYZ is transformed into the coordinate system fixed to the generated gear, the convex tooth sur-face is expressed. A similar expression is applied to the concave tooth surface. In this case, the difference of the turn-ing radius between inner and outer cut-ting edges E

xb that provides a crowning

to the tooth surface of the generated gear should be considered. The convex and concave tooth surfaces of the gear are expressed as X

g and X

g', respec-

tively. The concave and convex tooth surfaces of the pinion are expressed as X

p and X

p' respectively. Moreover,

the unit nomals of Xg X

g' X

p and X

p' are

expressed as Ng N

g' Np and N

p'.

CAD/CAM SystemThe numerical coordinates on the

tooth surfaces Xg Xg

' Xp and X

p' of the

spiral bevel gears were calculated based on the concept in the previous section. Moreover, those unit normals N

g N

g' N

p' and N

p were also calculated.

Table 1 shows the dimensions of the

Figure 4—Tooth profile of gear mod-eled using 3-D CAD system.

Figure 5—Tooth profile of pinion mod-eled using 3-D CAD system.

Figure 6—Gear workpiece on multi-tasking machine.

Table 1— Dimensions of spiral bevel gear

Pinion Gear Number of teeth Pitch circle diameter Pitch cone angle Hand of spiral

16 540.0 mm

21.801 deg. Right

40 1,350.0 mm 68.199 deg.

Left Normal module Shaft angle Spiral angle Pressure angle Mean cone distance Rm Face width Whole depth

24.9799 90 deg. 32 deg. 20 deg.

727.0 mm 185.0 mm 56.21 mm

Table 2 — Cutter specifications and machine settings

Cutter radius r c Radius difference Exb Radius of curvature of circular arc , ( ') Cutter blade module Pressure angle Base circle radius q Machine distance Md

ρ

450.0 mm 4.5 mm

3,500 mm 23.0 mm 20 deg.

546 .9441 mm 610 .4189 mm

ρ

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continued

not be machined efficiently due to the machining using only one point on the end mill. This manufacturing method was not suitable for the large-sized gear with a PCD of more than 1,000 mm. Moreover, the accuracy of machining was lacking. Therefore, a five-axis control machine (DMG Co., Ltd. DMU210P) was utilized. In this case, the plural surfaces—but not the installation surface—can be machined and a tool approach from an optimal direction can be realized using multi-axis control, as the structure of the two axes of the inclination and rotation, in addition to 3 axes of straight line, are added. It is therefore possible to use a thicker tool. This is expected to reduce the machining time and to obtain better roughness values. Cemented carbide radius end mills for hard cutting were used in the machining of the tooth sur-face. The number of edges was 12, and the diameters of end mills were 20 mm and 10 mm, respectively. Ball end mills were used in the machining of the tooth bottom. The number of edges was again 12, and the diameters of the end mills were 10 mm and 5 mm, respectively. The gear blank made out of 17CrNiMo06 was prepared. The tool pass was 1 mm for the large-sized gear. First, the gear blank was rough-cut and heat treated. The gear was then semi-finished with the machining allowance of 0.2 mm after heat treatment. Finally, the gear was finished with the machin-ing allowance of 0.05 mm by swarf cutting that is machined using the side of the end mill. Machining utilizing the advantages of multi-axis control and multi-tasking machine tooling in swarf cutting should deliver high accuracy and high efficiency.

Table 3 shows the conditions for semi-finishing and finishing in gear machining. Figure 6 shows the gear workpiece on the multi-axis control and multi-tasking machine; Figure 7 shows the cutting of the gear. The machining time of one side in rough-cutting is about six hours; and with semi-finishing and finishing, about seven hours. The machining was com-pleted with no complications.

Manufacturing of pinion. A five-

axis control machine (Mori Seiki Co., Ltd. NT6600) was utilizied for pinion machining. The radius end mills made of cemented carbide for a hard cutting tool were used in machining the tooth surface. The number of edges was 12, and the diameters of end mills were 20 mm and 16 mm, respectively. Ball end mills were used in the machining of the tooth bottom. The number of edges was 12 and the diameters of end mills were 10 mm and 5 mm, respec-tively. The material of the pinion was the same as that of the gear. The pinion blank was rough-cut and heat treated. The pinion was then semi-finished with the machining allowance of 0.2 mm after heat treatment. Moreover, the pin-ion was finished with the machining allowance of 0.05 mm by swarf cut-ting. Table 4 shows the conditions for semi-finishing and finishing in pinion machining. Figure 8 shows the pinion on the multi-axis control and multi-tasking machine. The machining time of one side in rough cutting was about eight hours, and with semi-finishing and finishing, about 32 hours. The machining was again finished without trouble.

Tooth flank form error and tooth contact pattern. The real gear and pinion tooth surfaces were measured using a coordinate measuring machine and compared with nominal data using the coordinates and the unit surface normals (Refs. 10–13). A Sigma M&M 3000 developed by Gleason Works was utilized. This measuring machine cor-

Figure 7—Swarf cutting of gear.

Table 3 — Conditions of gear machining

Processes Diameter

of end mill (mm)

Revolution of main spindle

(rpm)

Feed (mm/min.)

Depth of cut (mm)

Time/one side (min.)

Semi- finishing Finishing

20.0

20.0

2,000

2,200

1,150

1,100

0.3

0.05

110

310

Table 4 — Conditions of pinion machining

Processes Diameter

of end mill (mm)

Revolution of main spindle

(rpm)

Feed (mm/min.)

Depth of cut (mm)

Time/one side (min.)

Semi- finishing Finishing

16.0

16.0

2,800

3,300

1,100

1,100

0.2

0.05

480

1,440

Figure 8—Pinion workpiece on multi-tasking machine.

responds to large-sized spiral bevel gears. Figure 9 shows the measured result of the gear and Figure 10 shows that of the pinion. The tooth flank form errors are no more than about ± 0.06 mm and pitch accuracy is Class-1 JIS (Japanese Industrial Standards) for both the cases of the gear and pinion. We de not believe that these errors will have an influence on the tooth contact patterns for large-sized spiral bevel gears.

The gears were set on a gear mesh-ing tester and the experimental tooth

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However, production of the machine tools corresponding to the large-sized spiral bevel gears has recently decreased and the machines themselves are expensive.

In this paper, a manufacturing method of large-sized spiral bevel gears in the Klingelnberg cyclo-palloid system using multi-axis control and multi-tasking machine tooling was pro-posed. For this study, first the numeri-cal coordinates on the tooth surfaces of the spiral bevel gears were calculated and the tooth profiles were modeled using a 3-D CAD system. The large gears were manufactured based on a CAM process using multi-axis con-trol and multi-tasking machine tooling. After rough cutting, the workpiece was heat treated and finished by swarf cut-ting using radius end mills. The real tooth surfaces were measured using a coordinate measuring machine and the tooth flank form errors were detect-ed using the measured coordinates. Moreover, the gears meshed well and the tooth contact patterns were inves-tigated. As a result, the validity of this manufacturing method was confirmed.

(This work was supported in par t by Advanced Technology Infrastructure Support Services pro-moted by Ministry of Economy, Trade of Industry in Japan.)

References1. “Design of a Bevel Gear Drive According to Klingelnberg Cyclo-Palloid System,” KN 3028 Issue No. 3, (1994), p. 20.2. Townsend, D. P. Dudley’s Gear Handbook—the Design, Manufacture, and Application of Gears, 2nd Ed., McGraw-Hill, New York, 1991, pp. 20.42–20.45. 3. Stadtfeld, H. J. Handbook of Bevel and Hypoid Gears—Calculation, Manufacturing and Optimization, Rochester Institute of Technology, RIT., 1993, pp. 9–12.4. Nakaminami M., T. Tokuma, T. Moriwaki and K. Nakamoto. “Optimal St ructure Design Methodology for Compound Multiaxis Machine Tools—I (Analysis of Requirements and Specifications),” International

contact patterns were investigated. Figures 11 and 12 show the results of the tooth contact patterns on the gear tooth surfaces of the drive and coast sides, respectively. The tooth contact pattern is positioned at the center of the tooth surface and its length is about 50% of the tooth length, based on the analysis of the tooth contact pattern. The experimental tooth contact patterns are positioned around the center of the tooth surfaces of both drive and coast

Figure 9—Measured result of gear (µm).

Figure 10—Measured result of pinion (µm).

Figure 11—Tooth contact pattern of drive side.

Figure 12—Tooth contact pattern of coast side.

sides, respectively, although the length of the tooth contact pattern on the drive side is somewhat smaller. From these results the validity of the manufactur-ing method using multi-axis control and multi-tasking machine tooling was confirmed.

Summary/ConclusionsLarge-sized spiral bevel gears are

usually manufactured based on a cyclo-palloid system by a continuous cutting procedure using a special generator.

I

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Journal of Automation Technology, Vol. 1, No. 2, 2007, pp 78–86.5. Moriwaki T. “Multi-functional Machine Tool,” Annals of CIRP, Vol. 57, No. 2, 2008, pp. 736–749.6. Kawasaki K., H. Tamura and Y. Iwamoto. “Klingelnberg Spiral Bevel Gears with Small Spiral Angle,” Proc. 4th World Congress on Gearing and Power Transmissions, Paris, 1999, pp. 697–703.7. Kawasaki, K. and H. Tamura. “Duplex Spread Blade Method for Cutting Hypoid Gears With Modified Tooth Surface,” ASME Journal of Mechanical Design, Vol. 120, No. 3, 1998, pp. 441–447.8. Sakai, T. “A Study on the Tooth Profile of Hypoid Gears,” Trans. JSME, Vol. 21, No. 102, 1955, pp. 164–170 (in Japanese).9. Litvin, F. L. and A. Fuentes. Gear Geometry and Applied Theory, 2nd Ed., Cambridge University Press, UK, 2004, pp. 98–101.10. Kato, S. and T. Akamatsu. “Measuring Method of Hypoid Gear Tooth Profiles,” SAE Technical Paper, 1982, No. 810105.11. Gosselin, D., T. Nonaka, Y. Shiono, A. Kubo and T. Tatsuno. “Identification of the Machine Settings of Real Hypoid Gear Tooth Surfaces,” ASME Journal of Mechanical Design, Vol. 120, 1998, pp. 429–440.12. Fan, Q., R.S. DaFoe and J.W. Swangaer. “Higher-Order Tooth Flank Form Error Correction for Face-Milled Spiral Bevel and Hypoid Gears,” ASME Journal of Mechanical Design, Vol. 130, 2008, 072601–1–7. 13. Kawasaki, K. and I. Tsuji. “Analytical and Experimental Tooth Contact Pattern of Large-Sized Spiral Bevel Gears in Cyclo-Palloid System,” ASME Journal of Mechanical Design, Vol. 132, 2010, 041004–1–8.

Yoshikazu Abe is president of Iwasa Tech Co., Ltd. Based in Tokyo. Japan. He is also currently the chairman of Japan Gear Manufacturers Association (JGMA). Abe is a graduate of both Gakushuin University’s Department of Economics and Washington State University’s Department of Government.

Hiroshi Gumbara received his M-Eng. in 1976 and D-Eng. in 1994 from Tohoku University. He has been a professor at the Department o f Mechanical Engineering at Matsue Nat ional Col lege of Technology, Matsue , Japan from 2000 to pres-ent. His main research areas are the design and manufacture of gears.

Kazumasa Kawasaki received a B-Eng. in 1987 and M-Eng. in 1989 from Niigata University. He previously served as a research asso-ciate at the faculty of engineering at Niigata University, from 1989 to 2001. He received his D-Eng. in 1998 from Kyoto University. He was a Visiting Scholar at the Mechanical Engineering school of the University of Illinois at Chicago from 2000 to 2001 and has been an associate professor at the Center for Cooperative Research and the Institute for Research Collaboration and Promotion of Niigata University, Niigata, Japan from 2001 to present. Kawasaki’s main research areas are the design, manufacture and measurement of gears.

Isamu Tsuji is a gear technology engineer at Iwasa Tech. Co., Ltd., Tokyo, Japan. He specializes in the research and development of new gear manufacturing methods for straight, skewed and spiral bevel gears used in power plants and internal gears used in wind turbines. He holds BS and MS degrees in mechanical engineering from Keio University, Tokyo, Japan.

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Electric motors are used in a wide range of industrial applications. What most applications have in common is the need for their motor to be as efficient as possible and to have the longest possible lifetime without increasing main-tenance demands or failures. ABB’s synchronous reluctance motors are physically smaller in size, helping machine build-ers to design smaller, lighter and more efficient equipment. Additionally, the possibility of high-speed operation helps to eliminate mechanical power transmission elements such as gearboxes. This eventually enables the integration of the motor and the load equipment—now an increasingly com-mon request.

To answer the need for a motor that is more efficient, smaller and with a long lifetime and low maintenance needs, and that could also be perfectly adapted to variable speed drive (VSD) operation, ABB radically re-thought all tech-nology options. Starting a VSD motor is very different compared to a direct line connection start. This and other changes in boundary conditions highlighted potential oppor-tunities to simplify the motor design and improve efficiency.

Motoring Ahead

SYNCHRONOUS MOTORS CONTROLLED BY VARIABLE-SPEED DRIVES

ARE BRINGING HIGHER EFFICIENCIES TO INDUSTRIAL APPLICATIONS

Heinz Lendenman, Reza R. Moghadam, Ari Tami and Lars-Erik Thand

Management SummaryElectric motors in industrial applications account for approximately 60–65 percent of consumed

industrial electricity. Using energy effectively by increasing motor efficiency is at the center of con-tinued motor optimization. Major energy savings are also gained through the use of variable speed drive systems, and today this technology is adopted in as many as 30–40 percent of all newly installed motors. Sustainable use and investment also demand increased reliability and lifetime of a motor. The streamlined rotor structure of ABB’s synchronous reluctance motors eliminates rotor cage losses, thus increasing efficiency and compactness. The possibility of achieving standard power and torque levels at merely a low class-A temperature rise (60 K) improves the lifetime of the motor insulation and length-ens the bearing lifetime or greasing intervals.

One well known approach is the utilization of synchronous motors (SM). SMs with a 4-pole rotor operated at 50 Hz rotate in synchronism with the supply at exactly 1,500 rpm. The corresponding induction motor (IM), however, has slip losses and rotates only at 1,475 rpm for a chosen 30 kW example. In modern IMs with a short circuit rotor cage, the losses associated with the rotor amount to 20–35 percent of the total motor losses. Synchronous rotation eliminates most of these associated losses.

The elimination of these slip losses leads to an efficiency increase of about ~0.6 percent (220 kW motor) to 8 percent (3 kW), as well as a 20–40 percent increase in power and torque density for the same insulation temperature class.

Synchronous motors come in different variants—field-wound with brushless exciters; permanent-magnet (PM) motors; or as motors based on the principle of magnetic reluctance (often called a synchronous reluctance motor or SynRM). A SynRM rotor has neither a conducting short circuit cage—as does the IM—nor per-manent magnets or field excitation winding. Rather, the magnetic principle of reluctance is utilized.

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continued

Figure 1—A motor-and-drive system undergoing highly accelerated stress testing (HAST). (The above and all other pictures/images courtesy ABB).

Figure 2—The possibility of high-speed operation helps to eliminate mechanical power transmission elements, such as gearboxes.

The synchronous reluctance motor. Magnetic reluctance is the magnetic equivalent of the resistance in electrical cir-cuits. The rotor consists of one direction of least-possible magnetic resistance (d) and a perpendicular direction (q) with a high magnetic reluctance or good magnetic “insula-tion” (Fig. 3). Torque is produced as the rotor attempts to align the magnetically conducting direction to the stator field. The strength of the produced torque is directly related to the saliency ratio—i.e., the inductance ratio between the two magnetic directions of the rotor.

The invention of the SynRM concept dates back to 1923. However, at that time the motor type was not adapted for industrial use, due primarily to the lack of a direct online starting capability. But now—with the use of variable speed controllers—this obstacle has been removed (Fig. 4).

In 1982, NdFeB-based, permanent-magnet materials were discovered. The resulting new permanent-magnet (PM) motor technology was adapted for servomotors and is now emerging in many industrial specialty applications such as gearless, low-speed torque motors (Ref. 1). But once again, less attention was paid to the unpretentious SynRM.

In addition, not all earlier published work on the SynRM succeeded in demonstrating superior torque performance or reaching higher efficiency than the IM, as was expected from the calculations—a fact cited by experts and academ-ics as to why the SynRM is not used more often today. Presumably, these early results were due to less-optimized converter control. Indeed, some publications show very

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The industrial motor for VSD systems. In ABB’s SynRM rotor designs and drive control, the motor current, proportional to the inverse of power factor and efficien-cy—∝ 1/(η*cos[ρ])— is actually lower than that of a small-size induction machine at the same torque and speed. This is primarily due to the significant gain in efficiency. Only for large motors is the converter current higher than with an IM at the same torque. In general, the ABB SynRM oper-ates with the same frame size for the drive (e.g., ACS850) as the IM at the same power and torque level, albeit at the increased power density and higher efficiency than the IM. The motor efficiency increase translates to a nearly identical energy savings at the drive system level.

One other key advantage of ABB’s SynRM is the plain rotor structure. Without magnets or cage, the rotor construc-tion is more robust than either IM or PM machines. In addi-tion, no risk of permanent loss of performance exists due to potential de-magnetization in case of failure or overheating situations. The motor is inherently safe in operation since, without magnets, no back-EMF voltage is induced and the need for over-voltage protection of the converter becomes superfluous. Finally, rare earth materials for permanent magnets are relatively expensive and have currently been in limited supply for some markets due to the geographic concentration of the common raw materials suppliers, among other reasons.

Elimination of most of the rotor losses and the streamlined rotor structure result in a number of benefits for this motor and its connected load equipment (Fig. 3). A motor with this technology can be operated at the IEC standardized power level for the given frame size. In this case, the VSD efficiency gain ranges from more than 5 percent units for single kW machines to about 0.5 percent for the largest motors (frame 315). Consequently, where an IM would have run at class-F

q

T

T d Ψ

δ

ω

Pp = Pole pairs of the motor

2 Lq Ld

T = 3 Pp 1 - 1 ψ2 sin(2δ)

2 Innovation timeline in LV motors

year

140

120

100

80

60

40

20

0Wei

ght

of s

tand

ard

4-po

le,

4 kW

indu

ctio

n m

otor

s (k

g)

Technology comparisonmeasured ratings

5 hp = 3.7 kW

1900 1950 2000

sizeInduction

motorSynRM

Out-put

1003.3kWη=83%

4.3kWη=90%

+30-45%

160 22kW 29kW +32%

280 90kW 110kW +22%

Induction motor

ABB Synchronous reluctance Motor

Introduction of IEC standard

Introduction of SynRM

3 Loss distribution and e�ciency

Rated power (kW)

E�ci

ency

(%) d

ue t

o lo

ss re

duct

ion

98

96

94

92

90

88

86

84

1 10 100 1000

SynRM

IM

Induction motor

Loss reduction: 10 – 30%(Example: 15 kW @1500 rpm)

Synchronousreluctance

motorLoss origin

Rotor iron

Rotor conductor

WindageBearings

Stator iron

Stator conductor

For small motors at 3 or 4 kW level, as much as 60 percent more power can be obtained for the same tempera-ture rise.

Figure 3—Synchronous reluctance rotor and torque principle.

Figure 4—Innovation timeline in LV motors.

Figure 5—Loss distribution and efficiency.

promising results and have addressed the electromagnetic design aspects in great depth (Refs. 2–3). It is important to note the contrast of the SynRM to the switched reluctance—or stepper motor—with an entirely different stator, winding concept and non-sinusoidal current waves; a motor often considered unsuitable for industrial use due to high noise. A cited disadvantage of the SynRM is a higher current need for the same torque compared to the PM motor, since the rotor must be magnetized through the stator. However, the power factor as seen from the network is determined by the power converter and is in unity with all operating modes—even for the SynRM.

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temperature rise (105 K), the ABB SynRM operates merely at class-A temperature rise (60 K) (Fig. 4). In comparison, for a specific compressor at 4,500 rpm, the associated ABB SynRM features still lower bearing temperatures when run at true class-H rise (125 K) than the larger IM run at class-F rise (105 K). The motor was thus also called a “CoolMotor” (Fig. 5). This low-temperature operation improves the lifetime of the motor insulation and lengthens the bearing lifetime or greasing intervals. Motor bearings in particular require regular servicing and, according to some studies, bearing failure is the root cause of approximately 70 percent of all unplanned motor outages. The lower bearing temperature directly translates into longer greasing intervals, reduced maintenance and higher reliability. Even if a bearing eventually needs replacing, hav-ing no magnetic forces—unlike a PM motor—the bearing change is as easy as for an IM.

The technology enables good torque utilization at higher speeds. In another utilization of this technology, the opera-tion is maintained at the conventional temperature—often

Ambient temperature is the temperature of the air sur-rounding the motor. This is the threshold point or temperature the motor assumes when shut off and completely cool.

Temperature rise is the change within a motor when oper-ating at full load. The difference between the motor’s starting temperature and its final elevated temperature is the motor’s temperature rise.

The standard method of measuring temperature rise involves taking the difference between the cold and hot ohmic resistance of the winding. This averages the temperature change of the whole winding—including the motor leads, end turns, and wire deep inside the stator slots. Since some of these spots are hotter than others, an allowance factor uses the average temperature to indicate what the temperature

The low-temperature operation im-proves the lifetime of the motor insula-tion and extends the bearing lifetime or greasing intervals.

continued

180

155

130

120

105

40

0

Hotspot temperature margin

°C

Permissible temperature rise

5

10

10

15

Maximum ambient temperature

Insulation classMaximum winding temperature

A B F H 105 130 155 180

40 40 40 40

60 80 105 125

Temperature Classes

probably is at the hottest spot. This is known as the “hot spot” allowance.

Insulation classes group insulations by their resistance to thermal aging and failure. The four common insulation classes are designated as A, B, F or H. The temperature capability of each class is the maximum temperature at which the insulation can operate to give an average life of 20,000 hr.

Operating a motor at a lower temperature rise than allowed by the insulation class can change the motor’s ther-mal capacity, allowing it to handle higher than normal ambi-ent temperatures. In doing so, the motor’s life is extended.

The above graph shows the temperature ratings, tem-perature rise allowances and hot spot allowances for various enclosures of standard motors.

Figure—6 Temperature ratings and allowances for enclosures of standard motors.

B- or F-class. Since losses on the rotor are difficult to cool—compared to stator losses—their near elimination has a particularly high impact on the torque performance. For small motors at 3 or 4 kW level, as much as 60 percent more power can be obtained for the same temperature rise. For a 60 kW motor the gain is in the 40 percent range and for a 220 kW motor in the 20 percent range, compared to an IM. In most cases, the same power can be obtained from a motor by one or sometimes two frame sizes smaller than an IM. The reduction of the footprint is appreciable for all applica-tions that can utilize lower frame heights and smaller motors. An additional gain is the reduced heat load on nearby parts, particularly in closed cabinets. Even at this vastly increased power density, a further important advantage results from the removal of the losses on the rotor side; since much of the heat conduction through the shaft is eliminated, the bear-ing temperature, particularly on the drive-end, is reduced. Comparing an ABB SynRM with an IM at 6 kW, this can be as much as a 30 K reduction, with an approximately 15 to 20 K reduction typical over the entire range. This effect is par-ticularly pronounced at higher speeds, as well as for opera-tion at higher temperature classes. The generally high effi-ciency is maintained even at this high output. Furthermore, the ABB SynRM retains the excellent partial load efficiency curve typical of synchronous machines in that the efficiency remains high—even at partial load; a feature particularly appreciated in VSD drives for fans and pumps.

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the torque production and the magnetization current of the motor. Minimizing this reactive current was crucial in main-taining a favorable drive rating. The exact placement of the segments along the periphery is essential to create smooth torque during rotation, thus keeping the motor noise as low as with conventional motors. One result of this complex optimization using FEM, along with analytical and genetic algorithms, was that a 4-pole configuration is most suitable for the entire speed range up to 6,000 rpm.

To verify the reliability of this new rotor, extensive

5 Temperature scans from a thermal imaging camera

°C50

45

40

35

30

25Induction rotor Synchronous reluctance rotor

The performances of the new motor drive system are given for three IEC motor frame sizes

For full specifications check ABB web pages at www.abb.com/motors&generators.

Motor, temperature rise class F Drive, 400 V

Size PN nN PN nmax Eff TN MM Type code IN Noise Frame MDmm kW r/min kW r/min %(1/1) Nm kg ACS-850-04 A dBA size kg

100 4 1,500 4 2,250 84.3 25 22 010A-5 10.5 39 B 5

100 7.5 3,000 7.5 4,500 88.7 23 22 018A-5 18 39 B 5

100 13 4,500 13 6,000 90.5 27 22 030A-5 30 63 C 16

100 17.5 6,000 17.5 6,000 91.3 27 22 044A-5 44 71 C 16

160 26 1,500 26 2,250 91.7 165 180 061A-5 61 70 D 23

160 50 3,000 50 4,500 94.0 159 180 144A-5 144 65 E0 35

160 70 4,500 70 5,300 94.6 148 180 166A-5 166 65 E 67

280 110 1,500 110 1,800 96.0 700 640 260A-5 260 65 E 67

280 130 1,800 130 2,200 95.9 689 640 290A-5 290 65 E 67

Figure 7—Temperature scans from a thermal-imaging camera.

Drive conditions of pumps, fans, compressors, and mining and crane applications were emulated using methods for highly acceler-ated stress testing (HAST).

Figure 8—Performance of motor drive system for piloting.

Finally, these rotors feature about 30–50 percent reduced inertia due to the lack of cage and magnets. In highly dynamic applications such as cranes, this reduction implies further benefits in energy efficiency as well as faster lift cycles due to higher-speed ramp rates.

Rotor construction and reliability. Most technical aspects of drive systems with ABB’s SynRMs are directly based on existing technology. The housing, connection box, stator, winding design and technology and bearing options are identical to IMs. As the 3-phase currents are sinusoidal, the same drive products can control this motor type, provid-ed the firmware is optimized and includes this motor type. Only the rotor is different.

The rotor is less complex than in both IM and PM, as laminated electrical steel sheets are fitted to the shaft. The complexity is in the design. Extensive finite element simula-tions (FEM) were used to design the cross-section carefully in terms of electrical and mechanical properties. Important design choices made include the number of magnetic seg-ments and the exact shape of the air barriers. This determines

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of both worlds to users—all with value-added benefits as a bonus.

Heinz Lendenmann, Reza Rajabi MoghaddamABB Corporate ResearchVästerås, [email protected]@se.abb.com

Ari TammiABB Discrete Automation and Motion,Motors & GeneratorsVaasa, [email protected]

Lars-Erik ThandABB Discrete Automation and Motion,Motors & GeneratorsVästerås, [email protected]

References1. Haikola, M. “No Gears Required: ABB’s Direct Drive Solution Meets the Challenges of the World’s Most Demanding Processes.” ABB Review, April, 2009, pp. 12–15.2. Boglietti, A., A. Cavagnino, M. Pastorelli and A. Vagati. “Experimental Comparison of Induction and Synchronous Reluctance Motors Performance,” IEEE/IAS Annual Meeting, Oct., 2005, Vol. 1, pp. 474–479.3. Germishuizen, J. J., F.S. Van der Merwe, K. Van der Westhuizen and M.J. Kamper. “Performance Comparison of Reluctance Synchronous and Induction Traction Drives for Electrical Multiple Units,” IEEE/IAS Annual Meeting, Oct. 8–12, 2000, Vol. 1, pp. 316–323.

motor and drive system testing was conducted throughout development. Drive conditions of pumps, fans, compres-sors and mining and crane applications were emulated using methods for highly accelerated stress testing (HAST). HAST cycles were developed specifically for this motor to ensure robust lifetime performance, such as successfully conducting high-repetition-rate motor starts and stops at speeds above catalog-permitted values. The cycle count and overload conditions were dimensioned to correspond to a more than 20-year lifetime of rated operation.

Drive converter and control. Conventional ABB drive technology used for IM and PM motors, with standard direct torque control (DTC), was adapted to include the SynRM as a new motor type. Despite sharing many similarities with the PM motor, except for zero rotor flux, strong develop-ment focus was given to optimizing the torque production through maximum- torque-per-Ampere (MTPA)-control. This ensures that the drive current is kept minimal in each operating point. The control also includes capabilities for the field-weakening range; i.e., the speed range above the nomi-nal rated speed. A maximal rated speed of as much as 1.5 times nominal can be reached for much of the motor range. This drive control is a particularly important ABB result that enables this SynRM to reach appreciably higher torque den-sities than IMs.

The installation and operation of the power electronic drive for this motor is indistinguishable from driving VSDs with IM or PM motors. Standard features include automatic parameter identification based on nameplate values and sensorless operation. The motor does not need any speed sensors but nevertheless can maintain perfect speed accuracy as well as a high torque dynamic. The drive can even be dimensioned for specially requested overload and cycle load capability.

Performance preview. Since this motor, like the PM motor, always requires a VSD drive, matched pairs of motor and ACS drives are given as the standard recommendation for a range of power and speed levels (Fig. 6).

As a response to the key market trends of higher out-put, higher efficiency, longer service intervals and footprint reduction, a radical new motor uniquely suited for VSD systems is now available. The result is that increased power density of 20–40 percent when compared to an IM; a rotor construction without short circuit cage or permanent mag-nets; smaller motors; less heat generation and the highest possible efficiency for VSD systems is now a reality. A stan-dard IM fitted with a new rotor—combined with a standard drive with new software—results in a high- output, high-effi-ciency VSD system. The output and efficiency performance is comparable to a PM motor drive, while technologies associated with the robust induction motor deliver the best

An additional gain is the reduced heat load on nearby parts—particu-larly in closed cabinets.

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IntroductionGears are one of the critical

components in a two-wheeler engine, and in the gear itself, the lugs (Fig. 1) are one of the most critical features both in design and function. The lugs help in the meshing of one gear to another during shifting, and hence torque is transmitted through them (typically in the case of a two wheeler motorcycle). Because of their role, the lugs are subjected to severe bending loads and bending stresses.

The root fi llets of the lugs are the critical locations that endure the highest level of stresses under service loading. Figure 1 shows the stresses on the fi llet area of one of the lugs.

The goal of this paper is to throw light on the critical components of gears other than the profi le and to show the transmission designer how it is possible to carry out fi rst-hand analysis while optimizing the gear.

AnalysisThe author has used Pro/Engineer and

Pro/Engineer Mechanica for modeling and analysis of the gears (Figs. 2–3). Pro/Engineer is a parametric, feature-based, associative solid modeling software used extensively in the Indian automobile industry for engine modeling. Mechanicais a mechanical analysis package built into Pro/Engineer.

Our goal was to keep the stresses at the fi llet area as low as possible below the yield point of the material of the gear

Optimizing

GEAR LUG ROOT FILLET RADIUSDigendra V. Singh, Mahindra 2wheelers India Ltd., and Durga Shankar Gupta, Bajaj Auto Ltd.

Management SummaryIn today’s auto industry, all companies strive hard to maximize the durability of the engine and transmission components. In

gearbox design, most of the emphasis is usually placed on gear profi le analysis (i.e., bending damage, contact damage). In two-wheeler (motorcycle) gearboxes, the gear dogs (lugs) are very critical parts for gear shifting, as they mesh with corresponding kidney slots in the other gears while shifting from one gear to another. The lugs are a critical feature, because if any of them get broken during the operation of the engine, it will lead to severe damage of the surrounding engine components and render the vehicle immobile. This article concentrates on optimizing the gear lugs fi llet radius to reduce the bending stresses at the lug base area and thereby help in boosting gearbox durability in the initial design phase.

Figure 1—Stresses on the fillet of one lug.

Figure 2—Boundary condition being applied for gear lug.

Figure 3—Loading condition of the gear lug.

Figure 4—Line diagram of engine.

Figure 5—Fillet stress for a fillet radius of 0.3 mm.

Figure 6—Fillet stress for a fillet radius of 0.4 mm.

Intermediategears

Main shaft

Driveshaft

Rear tyre

Clutch

Average peak engine torque=8 Nm Primary Ratio=3.722 PCO of Lugs: 25mm No. of lugs: 3

fig 4

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would be a chance of the lugs slipping out of the matching slots in the other meshing gears (Figs. 12–13).

ConclusionBased on our analysis it became

quite clear that the stresses at the fi llet area are lower, with a larger fi llet radius. However, this is just the beginning of our analysis. We will address that topic in more detail in a future study. I

(16MnCr5, see Table 1). Figure 4 shows a line diagram of the engine.

The impact force acting on the gear lugs was calculated based on the peak engine torque. The average peak engine torque is 8 N-m, and the primary ratio is 67:18, or 3.722. Since the third gear is mounted (via spline) on the main shaft, the torque value on the third gear can be calculated as follows:

T3 = 8 N-m · 3.722 · 1,000 = 29,776

N-mmSince the bolt circle diameter of the

lugs is 25 mm, and the number of lugs is 3, the tangential force on the lugs is calculated to be 2,382 N.

Multiple analyses were carried out for fi llet radii ranging from 0.3 to 1.0 mm (Figs. 5–11). The maximum radius analyzed was 1.0, because if we increase the fi llet radius more than 1.0 mm, there

Figure 7—Fillet stress for a fillet radius of 0.5 mm.

Figure 8—Fillet stress for a fillet radius of 1.0 mm. Figure 9—Fillet stress for a fillet radius

of 1.2 mm.

Figure 10—Decreasing pattern of stress with an increase in fillet radius.

Figure 11—Although decreased stress is achievable with a fillet radius larger than 1.0 mm, the larger fillet radius causes other problems (see Fig. 12).

Figure 12—At a root fillet radius of 1 mm, there is a very close clearance between the adjacent gear and the lug (A, above). However, when the radius is increased above 1 mm, the gap decreases, leading to gear lug hammering, reduced shifting smoothness and improper gear meshing (B).

Digendra Singh is a senior engineer in the transmission R&D department of Mahindra2wheelers, located in Chinchwad, Pune.

Durga Shanker Gupta is a transmission engi-neer with Bajaj Auto Ltd., located in Chakan, Pune.

Table—Gear Material UsedSteel C Si Mn Cr S

16MnCr5 0.16 0.25 1.15 0.95 <0.035

Yield Strength: 695 MPa Ultimate Tensile Strength: 950 MPa

A

B

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hot peening is used widely to enhance the fatigue resistance of highly stressed metallic components such as aero-

engine fan blades, aircraft structural parts and automotive transmission sys-tems. Any metallic component that is

S subjected to cyclic stresses within its elastic limit can benefit from the shot peening process.

While the basic peening principle has existed for centuries, today the process is applied using highly control-lable—and, typically, programmable—machines. Peening is achieved by pro-pelling a stream of media—i.e., precise-ly manufactured, round steel shot, glass or ceramic beads—onto components at high velocity under fully controlled conditions utilizing a compressed air stream or, centrifugally, by means of a vaned wheel.

Compressive Stress Helps Prevent Crack Formation

Shot peening effectively applies residual, compressive stress to the sur-face of the component. This stress pre-vents crack initiation, as cracks cannot propagate in the compressive environ-ment generated by peening.

The compressive stresses are gener-ated when the impact of each particle of shot on the component produces a small indentation. It follows that, if the surface has been dented, the material beneath the dent has been compressed. Peening generates not just one dent but many thousands over the surface; eventually, the component is encased in a compressively stressed layer.

Measuring EffectivenessBecause the process is often used

to improve the performance of safety-critical components, it is important to ensure that sufficient stress intensity is achieved. This intensity is made possible by the proven “Almen strip”

Shot Peening TechnologiesENHANCE COMPONENT INTEGRITY

Paul Radulescu, Wheelabrator Group

testing procedure (the Almen strip and Almen gage were invented in 1942 by J.O. Almen). The Almen strip—manu-factured from spring steel to strict toler-ances of hardness, size and flatness—is peened on one side only. The effect of the induced, compressive stress on the strip results in bowing or curving. The extent of the curve is proportional to the energy imparted by the shot and is mea-sured on an “Almen gage.” The Almen strip arc height varies according to both the velocity and mass of the shot; i.e., the amount of energy imparted by the stream of shot and absorbed by the strip. X-ray diffraction techniques also provide an accurate method for measuring the actual stresses within the component and quantifying the actual effect of the peening process. Results are achieved by measuring the angle of reflection in relation to the angle of incidence that varies, dependent on material composition and residual stresses.

Reduced Friction, Less Corrosion and Wear-Resistant

In addition to preventing premature failure caused by fatigue, there are other important benefits from the process.

Fretting and galling. Components that are moving in relation to each other—as, for example, bolted or riv-eted assemblies, or within bearings as sliding or rolling members—can wear and fail as a result of the microscopic transfer of material from one surface to the other. But the surface finish produced by peening provides pockets for lubricant retention and reduces the

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surface area in contact under rolling or sliding conditions, thus reducing friction. In addition to its surface-hard-ening effect, peening also enhances the wear resistance of the material’s “skin.” These characteristics—in combina-tion—provide excellent anti-galling properties that result in harder-working, more efficient components.

Corrosion. Intergranular and stress-corrosion cracking are inhibited by shot peening, as it modifies the properties of the metal at a metallurgical level. The process advantageously alters the granular structure at and near the sur-face, thus producing a component less prone to corrosion.

Typical ApplicationsThe benefits of peening have been

well documented—both with compo-nents operating in a highly-stressed but relatively short-lived environment, such as motor racing, and for critical parts with a much longer and predict-able operating life in aero-engine and aircraft structures.

Process Selection is Critical to Performance

Decisions such as equipment and process selection and whether to employ a compressed air system with blast nozzles or a wheel blasting tech-nique, are of paramount importance when developing solutions for new components. However, selection of the correct equipment and process param-eters is complex; component variables such as throughput, size, shape, mate-rial, hardness, application and operating environment all have to be considered. The topography of the component is also an important factor. For instance, if a radius is smaller than that of the shot, a non-peened area will result. Sharp edges, blind holes or hidden areas also need special attention to ensure good coverage and to avoid damage.

Shot Peening in the Automotive Industry

The automotive manufacturing and subcontracting sector represents one of the largest users of the shot peen-ing process. This is due to the need to improve power-to-weight ratios, increase the fatigue performance of components and reduce manufacturing and energy costs.

Many developments in shot peening that were pioneered in the aerospace

sector have subsequently been trans-ferred to Formula 1 racing and then to production car manufacturing. This includes the peening of gears and other transmission components to increase torque performance.

To achieve the high degree of automation and control necessary for automotive manufacturing situations, modern peening machines incorporate programmable control and automated component handling systems. These operate in line with pre-set programs to ensure the precise repeatability of the peening effect, which is essential for volume production.

Reports detailing all process and machine characteristics can be pro-duced for verification and audit trail purposes.

DISA and Wheelabrator—a surface preparation technology manufacturer—have partnered to provide technologies to prepare, peen and finish an extensive range of components. Solutions include equipment for component corrosion protection, fatigue resistance, wear and weight reduction, cleaning, deburr-ing and peening; customized masking and material handling processes are also available. Any questions regard-ing shot peening equipment, service or new applications can be addressed by visiting the DISA booth (D2A) at IPTEX 2012 or by contacting:

For more information:DISA India LimitedPhone: + 91 80 [email protected] www.disagroup.comwww.wheelabratorgroup.com

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Management SummaryThis article describes some of the most important tests for prototypes conducted at Winergy AG during the prod-

uct development process. It will demonstrate that the measurement results on the test rig for load distribution are in accordance with the turbine measurements. The results of vibration measurements depend on the environment—i.e., the stand-alone gearbox has values other than those of the gearbox on the test rig or in the turbine. Measurement data show that resonance and Eigen frequencies are a critical issue; these effects cannot be eliminated, as they are endemic to every system. Multi-body analysis (MBA) is introduced here as a tool in calculating and simulating frequencies, amplitudes and gearbox behavior.

Product Development ProcessThe development of gearboxes for

wind turbines is based on the require-ment specifications provided by the customer. In these specifications all of the necessary needs—general descrip-tion, available space, power and loads,

Comparison of Test Rig and Field

Measurement RESULTS ON GEARBOXES FOR WIND TURBINES

Dipl.-Chem. Mark Zundel

(Reprinted with kind permission of 2010 VDI International Conference on Gears.)

Figure 1—Back-to-back test rig at Winergy/Voerde during prototype test.

specification; i.e., pinions, teeth, bearings, housing, etc.

• Mechanical design• Prototype testing

Prototype Testing on a Test RigAll prototypes are dynamics-tested

in a back-to-back configuration on a test rig (Fig. 1). Also, testing according to standard procedures of the gearbox manufacturer and customer require-ments is conducted and the design improved if the results warrant it.

There are three essential—yet dif-ferent—types of tests conducted during the prototype test phase:

• Dynamic tests on load, load dis- tribution and efficiency• Structure-borne noise and air borne noise tests and measure

ments• Lubrication tests; i.e., oil dis- tribution, leak tightness and cli- mate chamber testsTypically, load tests are carried out

etc.—are defined. The development follows a well-defined product life cycle management (PLM) process in which each step is determined.

The main steps—from specification to serial production—are:

• Calculation according to

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continued

4 ·

3

4.5·mn

3·mn

σ[N/mm²]

σ[N/mm²]

σ[N/mm²]

σ[N/mm²]

σ[N/mm²]

σ[N/mm²]

Figure 2—Distribution of strain gauges over the tooth width.

Figure 3—Application of strain gauges for load-distribution measurement on a sun pinion.

Figure 4—Typical results of a load-distribution measurement.

to check gearbox behavior; the gearbox is therefore typically tested at overload and according to the specification—occasionally up to 300% nominal load. The gearbox is then dismantled and every single part is inspected.

Load-Distribution MeasurementTo validate the gears’ calculated

and ground tooth profiles, a load-dis-tribution measurement must be done at different load stages. Strain gaug-es are therefore applied at the tooth to observe the forces during the tooth mesh over the whole tooth width; Figure 2 shows schematically the application of, for example, six strain gauges over the tooth width of a sun pinion. It can be seen that the width is divided in equidistant parts. It is impor-tant that the strain gauges are applied as following:

• No interference with each other• No influence of the border• Sufficient coveringWith this application (Fig. 3) on

several teeth of the gear, differ-ent load stages are tested; typically the load distribution is measured at 20/40/60/80/100 and 120% of nom-inal load. Since the profile is calcu-lated for one fixed load point, the correspondence is provided for only this. Deviations due to deformations are possible; nevertheless, it must be assured that the tooth contact is optimal over the entire range of performance. In doing so, a visual contact-pattern check after the test run must be done and the results considered.

During the test run, the measured force of each strain gauge is record-ed. Figure 4 shows a typical run of the curves for the strain gauges of two applied teeth. It can be seen on the left side that during the mesh, every strain gauge signal has a maximum relative stress dependent on mesh, loading and position. The maximum value of each strain gauge is plotted against its posi-tion for each applied tooth. The result-ing diagram on the right side shows the load distribution over the whole tooth width. This distribution is valid for one single meshing position, but will change for others.

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Sound and Vibration AnalysisStructure-borne noise and airborne

noise result from the meshing gears. The gear mesh works as a sound gen-erator and propagates over the housing. Gear mesh frequencies of the different stages can be measured on the gear-box housing and are taken into account as an indicator of gear quality. Every specification provides limit values of the amplitudes for each frequency or frequency range.

One must also be aware that reso-nance phenomena of the housing can increase those amplitudes, so attention paid to the mechanical design can aid in avoiding structural resonance.

To determine the Eigen frequen-cies of a gearbox, modal analysis of the individual parts, stand-alone gear-box and gearbox in the test rig configu-ration is done. Those results are then compared with the calculations. During the test run, an operational deflection shield analysis (ODS) is also conducted. Figure 5 shows the typical excitation and measurement points for a modal analysis of a gearbox on the test rig.

Figure 6 shows the result of a modal analysis of a gearbox hanging in a crane. It can be seen that no reso-nance frequency occurs between 0 and 200 Hz. Figure 7 shows the result of the modal analysis of the same gear-box installed in a back-to-back con-figuration on a test rig. It can be seen very clearly that resonance frequencies occur around 29 Hz and in the range of 85–100 Hz.

Figure 8 shows the mode shape of the gearbox in the test rig at 29 Hz; due to the fact that the gearbox is clamped in the test rig, an Eigen mode results that is not present when the gearbox stands alone. This fact must be taken into account when vibration values are discussed—not just regarding the behavior of the gear unit on the test rig, but on the turbine as well.

Multi-Body AnalysisTo understand more regarding

gearbox behavior in different environ-ments, multi-body analysis (MBA)is the tool of choice. Calculation of the relative movements of the gear-box and its parts—in all three spatial

Figure 6—Result of modal analysis of a stand-alone gearbox.

Figure 7—Result of the modal analysis of the gearbox on the test rig.

Figure 5—Typical excitation and measurement points for a modal analysis.

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continued

directions—and possible resonances is conducted. A model of the gearbox is built, and different operating con-ditions are analyzed. Figure 9 shows the model of the gearbox used for this analysis; Figure 10 shows the model of the gearbox in the test rig configura-tion.

Figure 11 displays the results of the time-based frequency analysis of the virtual measurement points at the torque arm. It can be seen that the simulation results correspond with the results of the modal analysis (Fig. 7). Resonances at 29 Hz and in the range of 85–100 Hz are also found in the simulation, meaning that critical fre-quencies or amplitudes can be calcu-lated. If more data about the installa-tion parameters of the gearbox in the wind turbine are available, calculation of gearbox behavior in the turbine is possible.

Comparison of Measurement Results from

Test Rig and Field MeasurementTest rigs and wind turbines are very

complex systems, with many compo-nents and many influencing param-eters. Therefore it is very important to analyze the behavior of a wind turbine gearbox in both situations. Figure 12 shows schematically the differences in the installation situation in the test rig and on the gearbox. One main differ-ence is the elasticity of the surrounding structure. While the test rig situation is very stiff, the situation on the wind turbine is weak. This leads to other Eigen frequencies and more defor-mation as the mode shapes change. Measurements of Eigen frequencies, vibration and sound were carried out and compared to the results of the test rig results. Unfortunately, since most of the measured data are proprietary, it is not possible to reveal them here.

To validate the load distribution values, measurements are done on the turbine. Given the varying, onsite wind conditions, it is not always possible to reach the same load level as on the tur-bine. Figure 13 shows the good correla-tion between the values on the test rig (lines) and the values on the turbine (dots).

Figure 8—Mode shape at 29 Hz of the gearbox on the test rig.

Figure 9—MBA model of the gearbox.

Figure 10—MBA model of gearbox and test rig.

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ConclusionThe comparison of different types

of measurements on gearboxes for wind turbines reveals that the oper-ational behavior of the gearbox is not determined solely by its proper-ties, but by application conditions as well; vibration behavior is particularly influenced by the clamping, dampers and base frame. Tests on the test rig are never an alternative to measure-ments on the turbine when determin-ing vibration values. Limit values are often given for several frequencies that cannot be achieved due to test rig influ-ences, as behavior on the turbine is sometimes very different. In accepting that premise, relying on final prototype gearbox testing conducted on only the turbine requires a good deal of consid-eration.

Kv·Kγ

KFβMaximumMean ValueMinimum

Kv·Kγ

KFβMaximumMean ValueMinimum

Figure 12—Installation conditions of the gearbox on the test rig (top) and turbine (bottom).

Figure 13—Comparison of load-distribution measurements.

Figure 11—Results of simulation of the vibration velocity of the gearbox.

Mark Zundel is a chemistry graduate of the University of Duisburg and a certified RAMS/L C C e n g i n e e r . From 2002–2008, he was a member of the condition monitoring depart-ment at Flender Serv ice GmbH, Herne focusing on condition diagnostics of gearboxes and driv-etrains. Zundel also worked on the develop-ment of an oil sensor while also serving as a lubrication and maintenance management con-sultant. Since 2008 he has worked at Winergy AG, Voerde as head of modeling, verification and tribology, concentrating on the planning of field and test rig trials of WT gearboxes, simulation of gearboxes during the develop-ment process and lubrication approvals, tests and tribology.

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KSPG ACQUIRES PLAIN BEARING OPERATIONS AT KIRLOSKAR OIL

KSPG, the auto-industry supplier and member of the Rheinmetall Group, has expanded its market position in the automotive market of India. The company has acquired the plain bearing operations of Kirloskar Oil Engines Ltd. (KOEL), located in Pune, India. In addition to the cur-

Suzlon Energy Limited recently announced its fourth consecutive order from GAIL. The order consists of 11 units of Suzlon’s S88–2.1 MW wind turbines, to be com-missioned in the states of Tamil Nadu and Karnataka by the end of fiscal year 2011–2012. This is GAIL’s fourth order with Suzlon, with the first two projects located in Gujarat. The first 4.5 MW project, comprising Suzlon’s S82–1.5 MW turbines, was commissioned in March 2010, and the second 14.7 MW project is currently under execution. A part of these projects is meant to fulfill GAIL’s captive power requirement, with the remainder for power sales to the respective local power distribution utilities. The sale of the power generated to the local power distribution utili-ties will be under the long-term purchase power agreement (PPA) at the fixed preferential feed–in tariff. Commenting on the order, Tulsi R. Tanti, founder, chairman and manag-ing director, Suzlon Group, says, “We are very pleased to announce our fourth order from GAIL, a ‘Navaratna’ PSU that has led the way with its approach to climate change mitigation and renewable energy. This order underscores our position as a partner-of-choice for large wind investors in India. With the strength of our future development pipe-line, our customized end-to-end offerings and our long-term service capabilities, we are best positioned to take advan-tage of the rapid growth of the Indian wind market. As we look ahead, we are very confident that we will maintain our leadership position in what is one of the most vibrant wind energy markets in the world today.”

For more information, visit www.suzlon.com.

Suzlon RECEIVES 23 MW ORDER FROM GAIL

Ashot Ashkelon Industries Ltd., a manufacturer and sup-plier of technologically advanced systems and components for aerospace, defense, automotive and other industries recently announced the purchase of Reliance Gear Corp, located in Addison Illinois, USA. Reliance Gear manufac-tures gear products and will serve as an additional manu-facturing site for Ashot and as a market base for develop-ing gears and transmissions for commercial and defense customers. This Reliance Gear Corp. acquisition augments Ashot’s capabilities and will contribute to expanding

Ashot Ashkelon PURCHASES RELIANCE GEAR

rently acquired activities, KSPG is manufacturing emission-control components and pumps for the Indian automotive industry at their own facility in Pune. KSPG Group has for years held a 20 percent stake in the Indian piston producer Shriram Pistons and Rings Ltd., New Delhi. It also has a licensing agreement for the development of cylinder heads, crankcases, bedplates and other castings with Jaya Hind Industries Ltd.

KOEL’s experience in bearing production goes back more than 60 years. The company’s bearing business gener-ated annual sales of some €20 million (approx. $26 million U.S.) in the fiscal year 2010/11 and has a workforce totaling 600 at the Ahmednagar and Pune locations. KOEL’s plain bearing lineup comprises engine bearings, bushings and thrust washers, chiefly for light- and heavy-duty automo-tive applications as well as agricultural equipment. For more information, visit www.kspg-ag.de.

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Global AC drives manufacturer Vacon has delivered an order of variable-speed AC drives, with a total power of 58 megawatts, for Indian-based AnRak Aluminium Ltd. The AC drives were delivered to a new aluminum refin-ery being built near the city of Visakhapatnam in India’s southeastern state of Andhra Pradesh. “We are proud that AnRak Aluminium decided to choose Vacon as their AC drives supplier for the new factory. Vacon is growing in India, and this delivery is an example of Vacon’s wide and reliable product offering combined with in-depth applica-tion expertise,” says Shailendra Salvi, managing director of Vacon India. The number of AC drives delivered to the site was more than 300. With powers ranging from 2.2 kW to 1.5 MW, the AC drives are used to control the various processes of the aluminum refinery. The factory is to be completed in March 2012 with a total production capacity of 1.5 million tons of refined aluminum per year. For more information, visit www.vacon.com.

Vacon DELIVERS AC DRIVES TO ANRAK ALUMINUM LTD.

Bosch Limited SEES 14.5 PERCENT GROWTH

Bosch Limited has registered a revenue growth of 14.5 percent in the third quarter of 2011 over the same period last year, despite a significant slowdown in most segments of the automotive market. Net sales and income from opera-tions in the third quarter of the year stood at Rs.1969.5 crores, which is 15.4 percent higher than the corresponding period in 2010. In the third quarter of 2011, profit before tax (PBT) stood at Rs.405.8 crores, registering an increase of 21.7 percent compared to the same period of 2010, and profit after tax (PAT) at Rs.288.1 crores, an increase of 22 percent.

The revenue growth is driven by good performance of the starters and generators division. Diesel systems have also contributed to revenues, with growth of 13 percent, and the automotive aftermarket division business grew by 13 percent. In the non-automotive business, the packaging divi-

Ashot’s marketing and manufacturing in the United States. Ashot’s capabilities are within four main areas of expertise: gears, transmissions and gearboxes for aerospace, automo-tive and defense applications; long and short shafts for turbine engines and other aerospace applications; high-lift aircraft actuation systems, including universal-joints, shafts, transmissions and gearboxes; and tungsten-based prod-ucts for aerospace, defense, medical and other uses. Ashot Ashkelon has 400 employees and 45 years of experience in the manufacturing field. As a vertically integrated company, Ashot has full manufacturing capabilities in-house. Ashot’s QA Department is AS9100B and ISO 9001 2008 certified, and all special processes are NADCAP approved. For more information, visit www.ashot.co.il.

sion business grew by a record 49 percent during the quar-ter, albeit on a small base. Additionally, power tools and security technology have seen a 19 percent and 17 percent growth respectively in the third quarter of 2011.

Overall, sales grew by 22 percent in the first nine months of 2011. The company posted net sales and income from operations of Rs.6066.2 crores in January–September 2011. Profit before tax went up by 29.3 percent at Rs. 1,211.2 crores and profit after tax was up by 29.8 percent, or Rs.841.4 crores, over the corresponding period last year. Treasury income has also significantly contributed to rev-enues. Income from treasury rose by 71 percent in January–September 2011 as compared with the same period last year.

Commenting on the company’s financial results, V. K. Viswanathan, managing director, Bosch Limited, says “The trying conditions prevalent in the economy have impact-ed every sector, including the automobile sector. Bosch Limited has been able to maintain reasonable growth despite slowing growth in the automotive sector. With dedicated focus in India, Bosch Limited will continue investing in capacity expansion, diversification and portfolio extension in order to cater to the market with better technologies for enhancing the quality of life.”

For more information, visit www.boschindia.com.

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C A L E N D A R

February 1–6—PlastIndia 2012. New Delhi. The scope for expansion and development in the Indian plastic industry was witnessed during PlastIndia 2009. Today, the industry offers higher-capacity machines, enhanced design capabilities, new products and applications. PlastIndia 2012 will display the latest equipment and machinery from leading plastic man-ufacturers. It will also offer the opportunity to see live demonstrations of plastic machinery first-hand. Major raw materials suppliers and manufacturers of plastic products will be present, offering the latest products and services. In addition, plastic technology sessions will be offered in the packaging, medical, automo-tive, agriculture, renewable energy and recycling industries. For more information, visit www.plastindia.com.

February 2–5—WIN-World of Industry 2012 Part 1. Istanbul, Turkey. Exhibitors of WIN-World of Industry have the opportunity to display their products direct-ly to top decision makers from around the world. The exhibition brings together multinational players into the fast growing markets in Eurasia and the Middle East. Part 1 will include exhibitions on metal work-ing, welding and surface treatment. The Industrial Activities Summit 2011, held parallel with WIN 2012, features well-attended conferences, seminars, round table discussions, panels, company and product presentations and forums. WIN-World of Industry Part 2 will be held from March 29–April 1 and will include exhibitions on automation, material handling, hydraulics/pneumatics and energy and electronic technologies. For more information, visit www.win-fair.com.

February 3–12—International Industrial Expo.Chandigarh, India. The Industrial Expo will provide numerous opportunities for attendees to discover the latest technologies and solutions in areas such as automotive, biotechnology, chemical, building and construction as well as the procurement/purchasing segments. Products include pulleys; v-belts; gears and gearing; gas generation and gas purification plants; lubricants and compressors; fasteners and clamping elements; industrial transmission/automa-tion; grinding wheels and abrasive belts; oil filtration and treatment equipment; heat treatment and sup-plies; hoisting equipment; air-conditioning/ventilation; welding equipment and factory automation. For more information, visit www.industrialexpos.com.

February 6–8—AdMet 2012. Maharashtra. Jointly organized by the Automotive Research Association of India, the Metrology Society of India and the National Physical Laboratory-India (CSIR-NPL), AdMet 2012 offers a unique opportunity to learn and share metrology advances, technology and prod-ucts. The theme of the 2012 exhibition is “Precision Measurement and its Application in the Auto Industry.” Topics include surface metrology; advanc-es and future metrology trends; flow measurements; optical metrology; calibration of equipment and machines; measurement system analysis; and many more. AdMet welcomes scientists, professionals, authors, manufacturers and delegates to share their thoughts and ideas concerning advancements in metrology and its application to the industry. For more information, visit www.araiindia.com.

February 10–12—Energy Tech and Enviro Tech 2012. New Delhi. EnergyTech will cover various sec-tors of energy, particularly new and renewable sources such as wind power, bio power, solar photo-volatic power, energy recovery from waste, etc. The Energy Sector, which accounts for about eight per-cent of Indian GDP, offers a wide canvas of oppor-tunities. EnviroTech will cover environment related technologies, products, methodologies, equipment and services. The Environment sector presents oppor-tunities in the areas of wastewater treatment includ-ing municipal sewage treatment; air pollution con-trol; hazardous wastes management; environmental instrumentation; consulting and training. Visitors to Energy-Enviro Tech include component manufactur-ers, end users, engineers, equipment and service pro-viders and many more. For registration information, visit http://www.enviro-energytechindia.com/index.html.

February 29–March 3—BIET 2012. BIET 2012 aims to act as a catalyst in exposure of emerging technolo-gies, adaptation of innovative concepts and techni-cal expertise. It will serve as a bridge between the consumers of technology and creators of machinery in helping both to understand each other’s needs to upgrade and modernize. Attending the conference and exhibition are a wide variety of decision makers, influencers and technical personnel from the light engineering sector. For more information, visit http://biet2012.asktradex.com/read.html.

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ad index

Capital Tool IndustriesPage 4Phone: +(91) 175-2351089, 2352326Fax: +(91) [email protected]

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INsight

The manufacturing sectors in India have grown tremen-dously and have reached a significant level as a result of increases in demands, positive market conditions and favor-able government policies. The country has been self-suffi-cient in the sector and promotes itself as one of the industry leaders. The forthcoming years are highly promising for the Indian manufacturing sector, which is well on its way to becoming the leading manufacturing location for companies around the world.

The industry for gears and power transmission equip-ment—which play a crucial role in the efficiency and high productivity of any manufacturing process—always lacked an exclusive platform to showcase its significance and offer-ings to the manufacturing sector of India. IPTEX was conceptualized to provide this platform for the mechanical power transmission industry to meet, share and showcase its latest technology and products under one roof to a wide range of user industry sectors.

The first expo, held in Mumbai in 2010, received an overwhelming response. The success of that first show encouraged and reiterated our belief in promoting niche industry segments. To create a tool for continued commu-nication among the industry players and users, we felt the need to go beyond exhibitions and give the Indian gear and power transmission industry players an opportunity to share information and knowledge. To provide this opportunity, Virgo Publications, a subsidiary of Virgo Communications & Exhibitions Pvt. Ltd., have partnered with Randall Publications LLC (USA), a trusted and well-respected name in the publication business catering to the gears and power transmission sector for almost three decades.

This magazine, Gear Technology India, is the result. Gear Technology India will publish on a quarterly basis. The maga-

zine will be made available to design and manufacturing heads of various industry segments from across sectors. Free sub-scriptions are available by filling out the form on page 51 or at www.geartechnologyindia.com/subscribe.php. Because of the strong partnership between Randall and Virgo, Gear Technology India is being officially launched on 9th February at IPTEX 2012 in Mumbai.

Virgo believes in working with niche industry segments and creating marketing and communications instruments through expos, conferences and trade magazines. A dedi-cated expo like IPTEX and focused magazine like Gear Technology India will help members of the manufacturing sector to constantly update themselves on current trends on technology, products, solutions and services offered by the gear and power transmission industries.

Through this true partnership with Gear Technology we promise to deliver better reach, awareness and visibility for the global industry players in India.

In other words, a true partnership for creating true value.

Anitha Raghunath,Co-Publisher of Gear Technology India and Director of Virgo Communications and Exhibitions Pvt. Ltd.

This column, INsight, is your forum to speak with the Indian gear and power transmission indus-try. Do you have ideas that will help your peers? Observations about the current state of the industry in India? Opinions about ways to improve opera-tions? We welcome your submissions. Please send your original INsights via e-mail to managing editor, Randy Stott, at [email protected].

IPTEX and Gear Technology India:

A True Partnership for Better Communication

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