01/12 gearsolutions by Tony Kadatz

Gear Solutions MAgazine

Processing New Gear Steels Processing New Gear Steels

Eliminating

Gear Whine Gearing Up for

Efficiency

Site Safety Tooth Tips HOT SEAT AGMA UPDATE Company Profile: Metlab

JANUARY 2012

Q&A: Jeff Estes

Partners in THINC/Okuma

JANUARY 2012

gearsolutions.com

See What The future Holds

Predictive Process Control the nIles Ze series has NEW features: high feed-rate grinding, module 25 (1 ndP), high-speed measurement for full contact grinding.

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features

Processing New Gear Steels By C.P. Kern, Dr. J.A. Wright, Dr. J.T.

Company Profile: Metlab

Sebastian, J.L. Grabowski, D.F. Jordan, and T.M. Jones

manufacturing and processing of a new class of vacuum-carburized gear steels with very high hardenability. Questek Innovations and Solar Atmospheres explain.

By Russ Willcutt

In terms of both knowledge and capabilities, this company is known for doing whatever it takes to find solutions to its customerâ&#x20AC;&#x2122;s mostcomplex problems.

Eliminating Gear Whine By Dr. Michael F. Platten and Melanie Fitton-Hayward

Advanced simulation techniques from Romax Technology eliminate gear whine problems in automatic transmissions.

Gearing Up for Efficiency By Miriam Metcalfe

Power losses and inertia matching affect the efficiency of linear drives, slowing motion and increasing unnecessary wear. Wittenstein provides an in-depth examination.

JANUARY 2012

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Resources MACHINES

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MARKETPLACE

ADVERTISER INDEX

JANUARY 2012 | VOLUME 10 / NO. 106 Gear Solutions (ISSN 1933 - 7507) is published monthly by Media Solutions, Inc., 266D Yeager Parkway Pelham, AL 35124. Phone (205) 380-1573 Fax (205) 380-1580 International subscription rates: $72.00 per year. Periodicals Postage Paid at Pelham AL and at additional mailing offices. Printed in the USA. POSTMASTER: Send address changes to Gear Solutions magazine, P.O. Box 1210 Pelham AL 35124. Publications mail agreement No. 41395015 return undeliverable Canadian addresses to P.O. Box 503 RPO West Beaver Creek Richmond Hill, ON L4B4R6. Copyright®© 2006 by Media Solutions, Inc. All rights reserved.

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

Departments Industry News Trends, data, and developments to keep you aware of what’s happening with your colleagues in the gear-manufacturing industry around the country and world.

Site Safety

Terry McDonald We read a lot about bullying in the news these days, but it’s not just confined to elementary school, and it can wreak havoc in the workplace.

Tooth Tips

William Crosher In this second installment in a series, the author continues his discussion of the different types of worm gears and the of applications in which they are used.

Hot Jack Seat Titus A process available in Russia for decades that has migrated to the United States stands to alter our thinking of nitriding as a case-hardening process.

Product Showcase News of products, equipment, and resources from across the manufacturing spectrum that will help propel your company toward success.

Q&A

Jeff Estes, director

Partners in THINC/Okuma

American Gear Manufacturers Association

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

JANUARY 2012

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LETTER

FROM THE

edITOR

We’ve seen collaborations between equipment and tooling manufacturers in recent years that are benefiting the gear manufacturing industry as a whole. Companies that might be considered—or actually are—direct competitors are coming together to provide tailored solutions to the challenges end users face. One of the best examples of this type of relationship is embodied in Partners in THINC, an Okuma initiative that you’ll read about in this issue of Gear Solutions. According to Jeff Estes—its director, and our January Q&A subject—current members representing the fields of robotics, measurement, workholding, material handling, lubrication, machines, cutting tools, and more are joining forces though Partners in THINC to help customers eliminate the “pain points” that are hindering production efficiencies. These teams will design new cells, redesign old ones, and even embark on greenfield projects involving new manufacturing facilities, depending on the client’s needs. Jeff says the camaraderie among these teams is genuine, with the focus being on solving the customer’s problems rather than jostling for position. This is very encouraging, especially during such rancorous times, and I’d like to applaud Okuma, Partners in THINC, and all its member companies for their important work. In this issue of the magazine we’re proud to share with you an outstanding paper titled “Processing New Gear Steels” by C.P. Kern, Dr. J.A. Wright, Dr. J.T. Sebastian, J.L. Grabowski of Questek Innovations and D.F. Jordan and T.M. Jones of Solar Atmospheres. I enjoyed this presentation during AGMA’s recent Fall Technical Meeting, and this paper generated an impressive response during the Q&A at the session’s close. Dr. Michael F. Platten and Melanie Fitton-Hayward describe advanced simulation techniques from Romax Technology in “Eliminating Gear Whine,” and Miriam Metcalfe of Wittenstein has penned the excellent article “Gearing Up for Efficiency.” This is a great mix of longtime and first-time contributors, and I’d like to thank everyone for sharing their expertise with us. In his discussion of case-hardening processes, “Hot Seat” columnist Jack Titus explores the properties and attributes of Catalytic Gas Nitriding, and William Crosher continues his multi-part series on worm gearing. In Terry McDonald’s “Site Safety” column we ponder bullying, revisiting an issue that most of us probably hoped had passed once we’d graduated from grade school. Problem is, you’ll find bullies in every setting, and throughout life, but when their behavior creates safety concerns in the workplace it’s time to take action. The AGMA discusses the upcoming Annual Meeting in their special section, and Metlab is our company profile. I’d like to thank co-owners Mark Podob and Jim Conybear for taking the time to outline the company’s impressive range of heat-treat capabilities. As an aside, I’m a member of the Gear Manufacturing Industries discussion group on LinkedIn, and I find myself responding to so many requests for information by encouraging people to visit our Web site and take advantage of our searchable archives. There is so much good information there, and so many great contacts to be found, that I really hope you’re harnessing the power of this free service. I look forward to hearing from you and reporting on your achievements in the New Year!

David C. Cooper PUBLISHER

Chad Morrison ASSOCIATE PUBLISHER

eDiTOriAL

Russ Willcutt EDITOR

sALes

Chad Morrison ASSOCIATE PUBLISHER

CirCuLATiON

Teresa Cooper MANAGER

Kassie Hughey COORDINATOR

Jamie Willett ASSISTANT

ArT

Jeremy Allen ART DIRECTOR

Michele Hall GRAPHIC DESIGNER

CONTribuTiNg wriTers WILLIAM P. CROSHER MELANIE FITTON-HAYWARD C.P. KERN J.L. GRABOWSKI D.F. JORDAN T.M. JONES TERRY MCDONALD MIRIAM METCALFE DR. MICHAEL F. PLATTEN DR. J.T. SEBASTIAN JACK TITUS DR. J.A. WRIGHT

Vertical Logo

PUBLISHED BY MEDIA SOLUTIONS, INC.

russ Willcutt, editor

Gear Solutions magazine editor@gearsolutions.com (800) 366-2185 x.205

P. O. BOX 1987 • PELHAM, AL 35124 (800) 366-2185 • (205) 380-1580 FAX

David C. Cooper PRESIDENT

Chad Morrison VICE PRESIDENT

Teresa Cooper

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OPERATIONS

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Coop

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INDUSTRY NeWS

New Products, Trends, Services, and developments

Gear Solutions Conducts Reader Survey

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As we embark on our ninth year of publication, we felt it was time to conduct a survey of our readers to make sure we’re hitting our marks. We would like to share some of the results with you here. • 73 percent of respondents rated the quality of Gear Solutions’ editorial content “above” or “well above” average as compared to other industry publications. • 93 percent rated the magazine’s technical articles as being “very useful” or “useful,” with similar numbers for other features such as the company profile, Q&A, columns, marketplace, and the news and product sections. • More than 70 percent of respondents find the search engine on the Gear Solutions Web site—where everything we’ve published is available for download, with no strings attached—to be comprehensive and useful.

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• In terms of job function, the majority of respondents were in the “design/research/development” category, followed by “manufacturing production,” “manufacturing engineering,” and “purchasing.” • Responding to the question “What actions have you taken as a result of reading an ad/article/feature/news release/ profile/column in Gear Solutions magazine?” the top answer was “discussed ad/article with others” followed by “visited the company’s Web site” and “saved ad/article for future reference.” • When asked “Where does your company find ideas about adopting gear manufacturing advancements?” more than 70 percent of respondents answered “Gear Solutions magazine.” • Given the opportunity to make general comments, responses included: Your magazine is above average, always worth

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

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reading; Gear Solutions magazine is a good resource for the latest events in gear manufacturing, and it also has very good technical articles which are educational in nature; Very valuable information, good work, thank you!; Gear Solutions is an excellent magazine that is helping us in a great way; I am very pleased with the quality and quantity of information provided in Gear Solutions, and; Very informative magazine, keep it up, love all the latest technological advances.

gear analysis software in addition to the demonstrations of many Ohio State gear test rigs. A unique feature of the course is the interactive workshop session that invites attendees to discuss their specific gear and transmission noise concerns. The round table discussions on day four are intended to foster interactive problem solving discussions on a variety of topics. The cost is $1,950.00, and those who wish to attend should contact Jonny Harianto at (614) 688-3952 or harianto.1@ osu.edu. Also visit www.gearlab.org.

Of the 30 questions developed, many help us to understand the makeup of our audience and their needs as Gear Solutions continues to evolve, both in print and online. As an example, when asked “What factors are presenting the most challenges for your operations?” the hands-down top response was “skilled workforce.” We have already acted on this input, developing a new jobs listing function for our Web site that will launch soon, with additional services in the works. Gear Solutions magazine is published by Media Solutions, Inc. (MSI), which also produces Wind Systems magazine and various custom publications. To learn more about MSI go to www.msimktg.com. The Web site for Wind Systems is www. windsystemsmag.com, and www.gearsolutions.com for Gear Solutions.

SECO/WARWICK Expands Staff SECO/WARWICK Corporation has announced that Bill St. Thomas has been added to its Vacuum Team sales staff as a regional sales manager. He brings more than 35 years of heat treating furnace sales experience and has extensive knowledge in the vacuum furnace, aluminum heat treating, and thermal processing markets. St. Thomas is a longtime ASM and Heat Treating Society member

FABTECH 2011 Breaks All Records

OSU Gearlab Presents Gear Dynamics and Gear Noise Short Course The Gear Dynamics and Gear Noise Short Course will be held March 13-16, 2012, at The Ohio State University. The course has been offered for over 30 years and is considered extremely valuable for gear designers and noise specialists who encounter gear noise and transmission design problems. Attendees will learn how to design gears to minimize the major excitations of gear noise: transmission error, dynamic friction forces, and shuttling forces. Fundamentals of gear noise generation and gear noise measurement will be covered along with topics on gear rattle, transmission dynamics and housing acoustics. This course includes extensive demonstrations of specialized

vacuum, CVD-graphitizing, and degassing. SECO/WARWICK has built some of the largest and technically advanced vacuum furnaces in operation today, developing advanced technologies like Universal HPQ™ (High Pressure Quench), PreNit® and FineCarb® LPC vacuum carburizing, fully automated control systems, and modeling software. Vacuum furnace configurations are available for vertical, horizontal, and elevator style furnaces. Both cylindrical and rectangular hot zones with metallic or graphite heating elements are available for both new and used equipment. Retech LLC provides vacuum melting equipment. SECO/WARWICK Worldwide manufactures industrial heat processing equipment including heat treating and brazing furnaces, vacuum furnace technology, atmosphere generators and aluminum reverb melting, and holding systems. SECO/WARWICK provides heat treating equipment and services worldwide for customers involved with primary aluminum, aluminum recycling, automotive, aerospace, commercial heat treating, HVAC, electronics, lighting, medical equipment, and nuclear applications. Contact Bill St. Thomas at (814) 853-6672 or st.thomas@secowarwick.com. Also go to www.secowarwick.com.

and has published several articles and presented many technical papers on a variety of heat treating applications. The Vacuum Team offers vacuum heat treating furnaces for hardening, tempering, annealing, solution heat treating, brazing, sintering, carburizing, carbonitriding, high

FABTECH 2011 shattered all records of previous shows, with the number of buyers walking the floor, educational conference attendance, and the overall square footage of exhibit space. The recently concluded four-day exposition and conference at Chicago’s McCormick Place welcomed a historic 35,457 attendees; a 35 percent increase over 2009, which was the last time FABTECH was held in Chicago. FABTECH is North America’s most comprehensive event for metal forming, fabricating, welding, and finishing companies. This year’s show had more than 1,300 exhibitors, filling a record 522,000 net square feet and attendees from more than 80 countries. “Exhibitors were enthusiastic about the activity level on the show floor and are looking ahead to 2012,” says Mark Hoper,

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FABTECH show manager. “Returning exhibitors were happy that leads were up from shows of the past few years and numerous first-time exhibitors proclaimed that the decision to exhibit was a great choice for them.” Many long-time exhibitors described FABTECH 2011 as their best show ever. “We’ve been exhibiting at FABTECH for at least 20 years, and in my 10-year tenure this show was our busiest. We received a record number of leads, and we were able to get our message in front of thousands,” says Betsy Van Duyne, marketing manager at Hypertherm. “The results from this show should prove to skeptics that manufacturing is alive and well in North America.” The many new exhibitors were also impressed with the value they received from the show. “We were first-time exhibitors at FABTECH, and it was an overwhelming experience,” according to Jim Gillespie, marketing manager at Fast-Rite International. “We have over 500 leads to process, and already have begun receiving orders. Considering it typically takes a year to complete a new customer sale, we’re quite happy!” Buyers were exposed to more than 500 new products and more than 75 new “green” products and technologies— a new feature on the FABTECH agenda. All products featured as green had to qualify as being more energy efficient, reducing waste and/or providing a safer and healthier environment for employees, customers, and the community. FABTECH is co-sponsored by five industry leading associations: the American Welding Society (AWS); the Fabricators & Manufacturers Association; International (FMA); the Society of Manufacturing Engineers (SME); the Precision Metalforming Association (PMA); and the Chemical Coaters Association International (CCAI). The 2012 show will be held in Las Vegas next November and return to McCormick Place in 2013. For more information visit www.fabtechexpo.com.

robots, and machine tools—has recently been named by Thomson Reuters as a 2011 Top 100 Global InnovatorSM. This new program is an initiative that recognizes the world’s most innovative organizations as a result of analyzing patent data and related metrics in a proprietary methodology. The program evaluates innovation performance of companies that invent on

a significant scale, work on developments that are acknowledged as innovative by others around the world and whose inventions are globally protected due to their importance. Methodology is based on four principle criteria: patent approval success rate, global reach of patent portfolio, patent influence in literature citations, and over-

faNUC Named top Global innovator FANUC Corporation—the world’s most diversified manufacturer of CNC systems,

JANUARY 2012

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all patent volume. The peer-reviewed methodology was executed using the Thomson Reuters Derwent World Patents Index® (DWPI), Derwent Patents Citations Index™, Quadrilateral Patent Index™, and Thomson Innovation®, the IP and intelligence collaboration platform. Comparative financial analysis was done using the Thomson Reuters Eikon platform, the

single source for turning financial information into action. This is the second top innovation recognition that FANUC has received in 2011. Forbes magazine also named FANUC one of the top 100 companies on their “World’s Most Innovative Companies” list. Since its inception in 1956, FANUC has contributed to the automation of machine

Complete Gear Manufacturing

tools as a pioneer in the development of CNC equipment. FANUC’s innovative technology has contributed to a worldwide manufacturing revolution, which evolved from the automation of a single machine to the automation of entire production lines. Today FANUC has more than 600 engineers working in R&D to provide the most reliable, efficient, and innovative CNC systems available. With 50 years of experience and more than 2,200,000 CNCs and 220,000 robots installed worldwide, FANUC is the undeniable global leader in CNC and robotics. Learn more at www.fanucfa.com.

New Comprehensive Catalog from Lincoln electric

• Serving the Gear Industry for Over 20 Years • Gear Grinding Services Featuring Newer CNC Gear Grinders • Calibrated Analytical Gear Inspection Equipment • Up to 200 Piece Lot Sizes • ISO 9001:2008

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Lincoln Electric’s Magnum® PRO welding gun line is now featured in a single comprehensive product catalog designed to help customers find the ideal gun for their welding application. The Magnum PRO product family includes semiautomatic MIG/Flux-cored guns with barrel-style or Curve™ handles, K126™ Innershield® guns for self-shielded flux-cored pipe and construction welding, fume extraction guns, as well as the Magnum PRO ThruArm and External Dress guns for robotic applications. The detailed catalog offers users an indepth look at the latest technology, features and benefits delivered by each gun in the Magnum PRO line. For example, Lincoln Electric Copper Plus™ contact tips are compared to competitive tips in lab testing and shown to provide longer life, resulting in fewer tip changes, higher productivity and lower overall cost of operation. The Magnum PRO guns featured in this new catalog are designed to withstand extreme welding environments, and were built with heat resistance and fast serviceability in mind. A significant feature of the MagnumPRO gun line is that a variety of gun models for various applications are supported with one set of gun expendable parts. The Magnum PRO 350 amp and 550 amp expendable parts are interchangeable and can be used on all Magnum PRO gun models. This results in a reduced investment in inventory of expendable parts by customers and distributors. Magnum PRO

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welding guns are available at a welding supply store near you. Call (216) 4818100 or visit www.lincolnelectric.com.

sionals, and plans to expand its online presence and explore other digital platforms to ensure manufacturers can receive their information in ways that suit their needs. Webster most recently served as business and automotive editor at the Detroit Free Press, where she has worked for the past eight years. Webster started as an

automotive reporter and was later promoted to automotive editor. She is credited with leading the newspaper’s awardwinning coverage of the unprecedented financial and automotive crisis in 2008-09. In January she was promoted to business and automotive editor, giving her expanded responsibilities for all of the newspaper’s business coverage in print and online.

SMe announces New editor in Chief The Society of Manufacturing Engineers (SME) announces that Sarah A. Webster has been named editor in chief of Manufacturing Engineering magazine. Her appointment was effective Monday, Nov. 7. She succeeds Brian Hogan, who retired after 13 years in the position. “Sarah Webster is a highly respected editor whose experience in both print and digital platforms will help elevate Manufacturing Engineering to the next level,” according to Greg Sheremet, publisher of the magazine. Manufacturing Engineering provides highquality technical information to more than 90,000 qualified manufacturing profes-

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Prior to joining the Free Press, Webster was a reporter for the Detroit News, the Lexington Herald-Leader in Kentucky and several newspapers in West Virginia, where she earned a bachelor’s degree in journalism from West Virginia University. She has covered a wide range of topics in her career, including automotive, health care, crime, and politics. Her work has won a range of state and national awards. “I am thrilled to be joining the fantastic team at SME,” Webster says. “I look forward to enhancing Manufacturing Engineering’s excellent reputation and serving the manufacturing community.” The Society of Manufacturing Engineers is the premier source for manufacturing knowledge, education, and networking. Through its many programs, events, magazines, publications, and online training division, Tooling U, SME connects manufacturing practitioners to each other, to the latest technologies and to the most up to date manufacturing processes. SME has members around the world and is supported by a network of chapters and technical communities. A 501(c)3 organization, SME is a leader in manufacturing workforce development issues, working with industry, academic, and government partners to support the current and future skilled workforce. Learn more at www.sme.org.

ExxonMobil Upgrades Lineup of Synthetic Circulating Oils ExxonMobil Lubricants and Petroleum Specialties Company, a division of Exxon Mobil Corporation, announces the launch of its next generation of Mobil SHC 600 Series lubricants, a family of high-performance synthetic circulating oils that are expertly for-

mulated to deliver long-lasting protection for equipment operating in extreme conditions. Developed through extensive laboratory and in-service testing with some of the world’s leading equipment manufacturers, the next-generation Mobil SHC 600 Series oils are recommended for

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use in 1,800 applications by more than 500 major equipment builders. Mobil SHC 600 Series lubricants also offer significant energy efficiency benefits. In extensive testing, next generation Mobil SHC 600 Series lubricants exhibited energy savings of up to 3.6 percent compared with conventional oils. Based on these exceptional results, Mobil SHC 600 Series oils have earned ExxonMobil’s official designation for “Energy Efficient” industrial lubricants and will feature the company’s proprietary “Energy Efficiency” logo on packaging. “Since their introduction more than 40 years ago, Mobil SHC 600 Series oils have been synonymous with exceptional performance and outstanding equipment protection, becoming the synthetic lubricants of choice for many successful companies in the global commercial and industrial marketplace,” says Michael J. Hawkins, Mobil SHC global brand manager, ExxonMobil Lubricants & Petroleum Specialties Company, a division of Exxon Mobil Corporation. “Today, with the launch of our next generation Mobil SHC 600 Series oils, we are once again raising the bar for synthetic lubrication technology and providing our customers with improved solutions to help enhance the life and performance of their critical circulating equipment.” Featuring the latest Mobil SHC technology with advanced synthetic base fluids and a proprietary additive system, the new Mobil SHC 600 Series oils can deliver a service life up to six times longer than competitive mineral oil based gear and bearing lubricants. The long-life benefits of Mobil SHC 600 Series oils enable maintenance professionals reduce waste, minimize removal costs and extend production schedules. In addition, the new Mobil SHC 600 Series lubricants deliver a number of other significant benefits, including outstanding low temperature fluidity to enable start up and operation at low temperatures and excellent resistance to rusting and corrosion for equipment protection. Mobil SHC 600 Series oils are fully are compatible with system components and materials used in equipment normally lubricated with mineral oils, which helps maintenance professionals minimize equipment issues during the conversion process. For more information visit www.mobilindustrial.com.

Erasteel Opens New Powder Metallurgy Facility in Sweden Erasteel, a 100-percent subsidiary of ERAMET, has inaugurated a new gas atomizing tower at its Söderfors plant in Sweden. Erasteel is the world leader for the production of high-speed steel through the process of gas atomized powder metallurgy. For all applications, tooling, or mechanical components, Erasteel recommends ASP steels produced by powder metallurgy. Thanks to this new facility, Erasteel will be able to extend its product range to new steel grades such as stainless steel, nickel, and cobalt alloys, and to reach new, fast growing markets. This will strengthen Erasteel further as the world leader in powder metallurgy using the gas atomizing process. In 2011, ERAMET Alloys is commissioning four strategic facilities (powder metallurgy in Sweden, titanium, aluminum and nickel alloys in France). ERAMET Alloys continues to focus its develop-

ment on new materials that, thanks to their specific properties, enable its customers to increase their performance and meet the challenges of sustainable development. “This investment in a very innovative technology opens new opportunities for Erasteel,” according to Patrick BUFFET, chairman and CEO of the ERAMET Group. “ERAMET benefits from its new technologies to bring to the market new, high performance solutions in the form of gas atomized powders of highly alloyed steels. Sweden holds key competencies in the field of powder metallurgy. This new investment shows our commitment to serve in the long term fast growing markets, like tooling, energy and in particular oil and gas.” ERAMET is a leading global producer of alloying metals, particularly manganese and nickel, used to improve the properties of steel, and high performance special steels and alloys used in industries such as aerospace, power generation, and tooling. ERAMET is also studying or developing major projects in new metals with high growth potential such as lithium, niobium, and rare earths, as well as in recycling. For more information go online to www.eramet.com and www.erasteel.com.

Partners in THINC Welcomes New Partner Okuma America Corporation is pleased to announce that the “THINC Developers Group,” a provider of developer and enduser feedback to Okuma to aid in the continuous improvement of THINC technologies, has joined Partners in THINC. The THINC

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Developers Group is a think tank focused on de facto computer architectures in the machine tool environment. The group provides a community for generating ideas, collaboration, promotion, and support of THINC related technologies for its members. “As experts in THINC related technologies, we aid in the continuous improvement of THINC®-OSP technologies and develop applications to help manufacturers improve productivity through the use of the THINC control,” according to group vice president, Rob Caron. The organization meets face-to-face at least three times a year and holds interim online meetings throughout the year. The group currently has two applications that are available for free download at www.okuma.com/thinc/thinc-apps. • USB Barcode Select Program: scan a barcode and have the associated part program automatically downloaded, p-selected into the control ready-to-run. • Variable Picture Application: automatically display a picture (.jpg) on the control screen by setting a variable in the part program, providing helpful images while the part program is running. The THINC Developers Group is open to active developers of THINC technologies on an invitation-only basis. The group facilitates THINC user education through Web-based events and user conferences which are open to all interested parties. To find out more or to potentially join the group e-mail thincdg@gmail.com.

Precision Gears for Aerospace & Commercial Applications

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Sandvik Coromant has announced the establishment of a new department focused on education. With this change comes a newly appointed director of education in the U.S., John Jacobsen. He previously held the position of director of business intelligence for three years at Sandvik Coromant U.S. in Fair Lawn, New Jersey. In his new role he will be responsible for overseeing all internal and external training and education activities in the United States. Continued On Page > 64

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Sandvik Coromant Appoints New Director of Education

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Okuma America Corporation is the U.S.-based affiliate of Okuma Corporation, a world leader in the development of computer numeric controls (CNC) and machining technology, founded in 1898 in Nagoya, Japan. Known for its technology leadership and world-class manufacturing, product quality and dedication to customer service, Okuma strives to be the machine tool solution provider to manufacturers worldwide. For more information visit www.okuma.com. Partners in THINC is a unique facility and concept offering integrated solutions and a one-stop shop designed to streamline current manufacturing processes, improve capabilities, or for exploring advanced manufacturing options. Each member brings specialized equipment, expertise and a commitment to provide the best possible integrated solutions to the end-user. For more information visit www.partnersinthinc.com.

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American Gear Manufacturers Association

Find Partnerships, Politics, and Predictions at AGMA’s Annual Meeting • Jim Meil, vice president and chief economist at eaton Corporation • Demographer and futurist ken Gronbach • Manufacturing specialist steve Barnhart • Comedian and author Connie Podesta

Our industry recovered from the 2008 recession quickly, and it appears that our growth will continue into 2012. even so, much of the non-manufacturing economy is growing slowly at best. One look at the nightly news will confirm that we are not out of the woods, not by a long shot. the international financial situation, our challenging political situation in the united states, and the technical changes within the industry all affect how you conduct your business in 2012 and impact how and when you make critical decisions. in March more than 250 of the current and future industry leaders from the american Gear Manufacturers association and american Bearing Manufacturers association will meet to discuss the issues affecting manufacturing at the 2012 annual Meeting. the meeting will be held March 1517 at the Hyatt regency Coconut Point resort and spa in Bonita springs, Florida. the planning committee has created a meeting experience that is sure to prepare you and your businesses for the coming year. in addition to the educational sessions, it will be a great time to engage in dialogue with your peers and keep the industry progressing on the post-recession road. the speaker lineup for the meeting is top notch. they represent topics you need to know about and don’t want to miss. You’ll find details on the following pages, but the speakers include: • Charlie Cook, the popular political analyst

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the aGMa/aBMa annual Meeting is a signiﬁcant networking event, ﬁlled with opportunities that allow you, the decision maker, to connect with peers and discuss current issues that affect your companies, your customers, and your supply chain. the networking is all about business, but it is also about sharing the company of your colleagues in the classroom, during the golf tournament, and the evening’s special events. the special events for 2012 include the celebration of st. Patrick’s Day on March 16. We will present an “irish eyes are smiling evening” highlighting traditional pub food, singing, and music straight from ireland. On saturday night the closing dinner will be followed with entertainment by the Capitol steps, a comedic troupe direct from the power seat of Washington, DC. they will perform “r” rated satire and poke fun at politicians, this political system, international relations, and everyday life. they perform quips and parodies that never go out of fashion. it seems there is no end to the faux pax or scandals that keep this material funny and fresh. this group will have you rolling in the aisles and provide a truly unforgettable experience. the Hyatt regency Coconut Point resort and spa promises to be a comfortable and convenient setting for peer-to-peer interaction. this four star resort was recently named as one of Travel + Leisure magazine’s 500 best hotels. it is located on 26 acres on estero Bay on the Gulf Coast of Florida, only 30 minutes from the Ft. Myers airport. the resort has copious activities for you and your families, including a water taxi to their private beach where you can search for sharks’ teeth, collect shells, or view the pristine aquatic preserves and watch the animals in their native habitat. Further information about the joint meeting—including registration, hotel reservations, agenda, and program updates—is located on the subsequent pages or online at www.agma.org. i look forward to seeing you in Florida and showing you how this experience can impact you personally as an industry leader and your company as you plan for the future. this is a can’t miss event in a perfect setting, accompanied with interesting colleagues, great food, and golf, all wrapped up into a memorable three-day opportunity. regards: Madelaine Morgan, CMP Director of Meetings american Gear Manufacturing association (703) 684-0211 morgan@agma.org www.agma.org

JANUARY 2010

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Facing Our Futures Join aGMa and aBMa for a packed agenda and a little bit of fun in one of america’s top resort destinations at this year’s annual Meeting. this event brings together CeOs and leaders from the gearing and bearing industry. Over the course of two and a half days, attendees have many opportunities to network with colleagues both at educational presentations and during social activities. the presentations are timely and highlight the current business environment. Plus, Friday night will bring out the irish in all of us for st. Patrick’s Day, and on saturday night the always funny Capitol steps will put the “mock” back in democracy. Featured presentations include: Thursday, March 15, 2012

Stand Out from the Crowd: How to Out-Think and Out-Perform the Competition

Connie Podesta, Motivational speaker, author, executive Coach and industry expert in today’s world, there is no such thing as “business as usual.” the game has changed, and the competition is closing in with new strategies. if

you want to stand out and succeed in an environment where dramatic change happens at the click of a mouse, then you will have to out-shine past performance, out-think old ideas, and outmaneuver anyone who says it “can’t be done.” You will need to close the gap between where you are now and where you want to be. Join Podesta, whose message of humor and motivation will inspire you to make those personal changes that will put you on the road to success, health, and happiness.

Calendar of Events

Whether you’re looking for technical education, networking opportunities, or a way for your voice to be heard in the standards process, the AGMA has something to offer you. If you would like more information on any of the following events visit www.agma.org or send e-mail to events@agma.org. ** Event open to AGMA members only. Not a member? Send e-mail to membership@agma.org.

WebEx

WebEx Des Plaines, IL

Aurora, CO

Spline Committee Meeting

4-5

January

Metallurgy & Materials Committee Meeting

10 Enclosed Drives for Industrial

Orlando, FL

Wind Turbine Committee Meeting

Nomenclature Committee Meeting

17-18 19

Mill Gearing Committee

Applications Committee Meeting

AGMA Webinar Series: Charting the Course through Profound

Technical Division Executive Committee Meeting

24-26

Gearbox CSI – Forensic Analysis of Gear and Bearing Failures

WebEx Online

Concordville, PA

WebEx

gearsolutions.com

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nalysis es

Friday, March 16, 2012

How to Profit from the Coming Demographic Storm

Kenneth W. Gronbach, President of KGC Direct, LLC Join author and expert demographer Gronbach on an exciting journey into the fascinating world of shifting demographics. His views are counter-intuitive, global, long term and very macro. He is able to forecast societal, political and economic changes with uncanny accuracy. Gronbach is forecasting that manufacturing will return to our continent with a vengeance. He will show why changing demography bodes well for the United States and the Americas and why the best days for the United States are ahead of us, not behind us. Successful Business Growth; Five Guiding Principles Steve Barnhart, Manufacturing Specialist of IMEC (Illinois Manufacturing Extension Center) This presentation will focus on how to grow your business by entering new markets and expanding your existing markets or products. Barnhart will focus on the key operational issues to promote success including how to evaluate your company’s readiness for growth through market or product diversification. Armed with the Five Principles from this presentation, you will be able to assess your company’s opportunity for growth; where, when, and how that should occur; and what it takes to complete it. Following this presentation a panel of our industry colleagues will

Orlando, FL

present first-hand accounts of their successes and challenges with new business ventures. Panelists include: • Rock Baty, President and CEO, NN Inc., Johnson City, TN • Eduardo Garza Junco, chief Executive Officer, Frisa Industries, Monterry, Mexico • Dennis Racine, President and General Manager, Penn Machine Company, Johnstown, PA Friday, March 16, 2012 Fork in the Road–Growing or Slowing? Jim Meil, Vice President and Chief Economist, Eaton Corporation Will the Euro currency crisis be the catalyst for catastrophe or is it a problem with a solution? Will the momentum of North American markets be maintained, or muddled up in a Washington morass? What about China’s bubble or the trouble in Brazil? Will Obama and Boehner fumble and/or Merkel and Sarkozy stumble? Most important of all, will North American and global manufacturing be headed up or down in 2012 and beyond? Meil as he addresses the global economic business concerns that keep us up at night. He has been invited back to offer his keen economic analysis, always on point and relevant. He has that unique perspective from within manufacturing and keen knowledge of what impacts our sector of the economy.

Orlando, FL Bonita Springs, FL

Sound and Vibration Committee Meeting

Helical Enclosed Drives High Speed Units Committee Meeting

25-26

February

Helical Gear Rating Committee Meeting

9-18

Trade Mission to India and IPTEX 2012

2012 AGMA,/ABMA Annual Meeting

15-17

March

Ft. Myers, FL Several cities in India WebEx

Available Year-Round

Online Workforce Education

Gain basic gear training in three courses: Fundamentals of Gearing, Gear Inspection, and Hobbing. Go to www.agma.org/events-training/detail/online-workforce-education.

JANUARY 2010

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Political Outlook for November, 2012 Charlie Cook, editor and Publisher, Cook Political report Cook is another returning favorite to the aGMa/aBMa meeting. He will have his pulse completely focused on the 2012 presidential election and other key races. By March, 2012 the frontrunner republican candidates will have changed several times, the battle lines will be formed; and the race will be in full swing. no one can deny the fact that the 2012 election will be truly historic. When Cook makes a pronouncement based on his analysis of the political scene in america, people who want to be “in the know” sit up and listen. For more than two decades he has been Washington’s most trusted— and most accurate—voice on all things political, whether it’s the outcome of a Congressional, gubernatorial, or presidential election. Cook’s expertise has been featured on the aBC, CBs, Good Morning america, the today show, nightline, Meet the Press, and this Week. He founded the Cook Political report in 1984 and became a twice-weekly columnist for roll Call, Capitol Hill’s premier newspaper, before joining the national Journal Group in 1988. He has also been an election night analyst for Cnn and CBs news and for every presidential election since 1994 for nBC news. in addition to hearing world-class speakers, annual Meeting participants will get to take advantage of networking opportunities in an impressive setting at the Hyatt regency Coconut Point resort & spa. the Hyatt regency Coconut Point resort and spa is located on 26 acres of the estero Bay and

aquatic Preserve on the Gulf Coast of Florida. recently the resort was named one of Travel + Leisure magazine’s 500 best hotels. the state of Florida has presented the resort with Florida Green Lodging’s three Palm eco-friendly certification. this pristine area offers limitless recreation options, including fishing, kayak rental and a water taxi to Big Hickory island Beach, the resort’s private beach area, just 15 minutes from the hotel. the more adventurous types can pack a picnic, rent a kayak and cruise the Bay where you can take a chance that the dolphins and manatees will be active. You may also view osprey, eagles, and herons as well as several species of sea turtles in their natural habitat. You could collect shells at the private beach, or just soak up the sunshine and explore the white sandy beaches. the land lovers can “veg out” at the one of the four pools at the resort, or plunge down the 140-foot water slide. save enough time to pamper yourself with a treatment or two at the award-winning stillwater spa. their tranquil environment provides the perfect backdrop for a multitude of services—everything from a full body massage to a short touch up at the salon. there are six restaurants at Coconut Point, including tanglewood, winner of aaa Four Diamond award. enjoy some of the local fare, including fabulous ceviche and local fresh fish caught just a short distance from the resort. to find out more about the annual Meeting or to register visit www. agma.org.

agMa leadership Board of Directors norbert Benik: VP of Industrial Sales, Ontario Drive & Gear, Ltd. Jim Bregi: President, Doppler Gear Company sulaiman Jamal: Managing Director of Bevel Gears (India) Private Limited tom Marino: President & CEO, Gear Technology Gordon new: Managing Director, Ronson Gears Pty, Ltd. Bob Phillips: Senior Vice President, Gleason Cutting Tools Corp. Bob sakuta: President, Delta Gear kyle seymour: President & CEO, Xtek, Inc. Mike smith: Vice President of Sales and Marketing, Capstan Atlantic Mike suter: Vice President of Marketing, Emerson Industrial Automation Dirk Wernecke: Global Manager, Pricing, The Timken Company

contact the agMa

1001 N. Fairfax Street | Fifth Floor Alexandria, VA 22314-1587 (703) 684-0211

www.agma.org gearsolutions.com

GearSolutions_January12.indb 20

Executive Committee chairman: Matt Mondek President, Cotta Transmission Company, LLC treasurer: Louis Ertel President & CEO, Overton Chicago Gear Corp. chairman, BMec: John Strickland VP of Marketing and Strategic Planning, Fairﬁeld Manufacturing Co., Inc. chairman, tdec: Dr. Phil Terry Chief Metallurgist, Lufkin Industries chairman emeritus: Dave Ballard Director of Marketing & Business Development, North & South America, Siemens Industry, Inc.

Staff

Joe T. Franklin, Jr., President Charles Fischer, Vice President Technical Division Jan Potter, Vice President Membership

general requests: webmaster@agma.org Membership questions: membership@agma.org gear expo information: gearexpo@agma.org technical/standards information: tech@agma.org agMa Foundation: foundation@agma.org

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siteSAFETY terryMcDONALD Member of the ANSI Subcommittee on Gear Safety

We read a lot about bullying in the news these days, but it’s not just confined to elementary school, and it can wreak havoc in the workplace. I doubt that many of us have completely avoided crossing paths with a bully or two in our lives. The first encounter may have been on the playground or in the hallways of elementary school, when someone—for whatever reason—decided to make fun of our size, or our hair, or the way we were dressed. And even though teachers will generally intervene when they see someone getting pushed around by a bully, there are just too many dark corners and wide-open spaces for them to keep track of. So even if a teacher did save your neck during third period, that just meant you’d get what’s coming (and then some) at the bus stop that afternoon. And it also has to be said that some of us might not have been on the receiving end, because something strange can happen when your buddies are goading you to prove how tough you are by picking on somebody you have some kind of advantage over. That can be an embarrassing thing to have to live with, but it also provides insights into why bullying can happen. First of all, bullies are not strong or tough. They are shallow and weak. The reason a person wants to hound another one, either physically or verbally, is because they feel inadequate themselves and think acting like a hot shot will make them popular, or feared. They are falling back on the mistaken belief that everybody admires strongarm tactics, and that muscle over mind is the rule of the day. But I’m not just talking about getting physical here, because we all know that psychological abuse can be much more painful, eating away at your self-esteem right at the time when you’re trying to figure out how to get along with other people in public settings. And as sad as it is that this happens so often in grade school, it’s even worse when you discover that it doesn’t end with graduation. Bullies are everywhere. You encounter them when you’re driving your car, walking through a crowded mall, or even swimming in a hotel pool. The biggest problem, though, is how often you encounter them in the workplace, because that’s a harder situation to avoid. Maybe you’ve worked at a manufacturing company for 10 years, and a “new guy” who’s trying to prove himself starts making mean-spirited comments and snickering to his buddies whenever you walk by. On the other hand, maybe you’re the new hire and somebody thinks they’ve got to see what you’re made of before you’ll be accepted. Or maybe you’re from another country or ethnic group, and we all know what an easy target that can make you with some people. If this is basic human nature, though, then what are we as employers to do?

About the author: Terry McDonald is partner and manager of Repair Parts, Inc., and a member and past–chairman of the ANSI B11.11 Subcommittee on Safety Requirements for Construction, Care, and Use of Gear Cutting Equipment. Contact him at (815) 968–4499, rpi@repair–parts–inc.com, or [www.repair–parts–inc.com].

First of all, you’ve got to put a stop to it, but you need to handle it in the right way. Nobody has the right to abuse another person, whether it’s physically or mentally, and we have a responsibility as safety professionals to make sure we extinguish sparks before they become a flame. If you see someone engaging in this type of behavior and it’s creating a dangerous situation—taking people’s minds off the machines they’re operating, for instance—then you’re probably within your bounds to step in and break it up. Another situation might involve practical jokes that clearly aren’t meant to be funny, but to humiliate the person they’re done to, like doing something to make someone trip and fall. That involves safety, so it should either be addressed or reported. To be honest, though, any situation involving abuse of any kind should be reported to upper management, who might then forward it to human resources. If the person is a new hire and still under probation, then this is exactly the kind of behavior such rules were put in place to catch. If the employee has been there for awhile, then it needs to go on their record in case it’s part of a trend in his or her behavior.

“Nobody has the right to abuse another person, and we have a responsibility as safety professionals to make sure we extinguish sparks before they become a flame.”

As for the person on the receiving end, it might be a good idea to pull them aside without making it too obvious and have a private conversation about what’s been happening. Sometimes you’ll gather more information about what’s happening both within and outside of the workplace—did somebody dent another person’s care in the parking lot, or take their lunch from the refrigerator by mistake?—that will help you to address the situation in a productive way. Reassigning workers to different parts of the plant can sometimes help, but the most effective response is to stop the abuse, take the proper steps in terms of reporting what’s happened, and talk to the people involved. That way the bully knows you’re onto him, and the victim knows it isn’t being ignored. Whether you’re in an office setting or on the production floor, there’s always the chance that you’ll run into some type of bullying behavior, and it doesn’t matter if you’re the target or a mere bystander, do something. After all, if you’re not working on a solution, then you’re part of the problem!

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This month we will discuss threads, effective length, and tooth thickness: The worm may be designed with any number of threads, or as they are also called, starts. When the worm is viewed from the end of the worm, the number of threads can be easily seen and counted. The reduction ratio is determined by the number of teeth in the gear divided by the number of threads. Normal practice is to use from one to 12 threads. The number of threads is usually limited by the available tooling. For example, one major manufacturer advertises their thread grinding capacity up to 21 threads. Each thread takes a share in driving the wheel. The general rule is to have the sum of the number of threads and worm gear teeth to be 40 or more. Regardless of the odd number stated previously, an even number of threads should be selected when the total number of threads exceeds five. As the wheel diameter increases with the center distance, the number of threads selected increase. Using a nominal ratio of 15:1 as an example, the practical selection would be: • 3" centers, two threads, 31 teeth • 28" centers, five threads, 76 teeth The common practice with globoidal worm gears is to proportion the gear tooth and worm thread thickness as follows: axial gear tooth thickness equivalent to 55 percent of the circular pitch; axial worm thread thickness equivalent to 45 percent of the circular pitch. The backlash is subtracted from the axial worm thread thickness. The face width of the gear is generally equal to or slightly less than the worm’s root diameter. Additional face width is a waste of material and does not add a proportional capacity. Globoidal worm thread length cannot extend beyond the base circle. When the worm thread extends beyond the effective length, it must be relieved to avoid interference. The effective length should be the base circle diameter, minus approximately 0.10 times the center distance. When the actual length is less than the effective length, the rating must be reduced accordingly. In cylindrical worms several different methods can be used to determine the normal chordal thread thickness. The tooth thickness and the worm’s space width are usually defined with reference to the normal section. The calculation is necessary to ensure that the worm thread or worm gear tooth tip thicknesses do not come to a point and are suitable for the loads imposed.

TOOTHTIPS williamCrosher

Author, engineer, and former director of the National Conference on Power Transmission

In this second installment in a series, the author continues his discussion of the different types of worm gears and the wide variety of applications in which they are used. The cylindrical worm thread length is calculated based on the worm gear pitch diameter. The minimum length must be such that the face width is equal to five times the worm’s axial pitch so that there are three contacting threads and an extra thread at each end. Ratios: Worm gears are frequently produced to a series of standard center distances. At each center distance a wide range of standard ratios is available, in some instances ranging from 5:1 to 100:1. For a given center distance the pitch circle diameters are fixed, as more teeth are designed into the fixed diameter worm wheel the teeth will become smaller, reducing their rating. By increasing the number of threads the wheel teeth can be maintained at an optimum number for that diameter of wheel. The diameter of the worm has no influence upon the ratio of the gearing, but the root diameter must be large enough to prevent any excessive deflection. When the centers are fixed the desired ratio is obtained from the worm thread lead and the number of threads. As the lead is increased, the thickness and height of the wheel teeth must be increased accordingly. The lead is the distance, measured parallel to the axis that the worm thread would advance in one complete revolution. The usual standard range of worm gear ratios are between 5:1 and 60:1, lower efficiencies are to be expected with the higher ratios. When two or three sets of worm gears are used within a single housing their combined ratios provide the highest overall ratio that can be obtained in a single housing, with the possible exception of epicylic gear units. Single reduction worm gears have been built with ratios that range from 1:1 to 300:1. Worm gears with a ratio approaching unity have a load capacity several times higher than standard straight-faced spiral gears. They are difficult to produce and require special machines but have many uses because of their high efficiencies and load capacity. The sets used in the Sunbeam shaft driven motorcycle of the 1950s were an interesting example of low ratio worm gears. The six-thread worm and gear had a ratio of 3.833:1 and were designed on centers of 2.25". We will continue our discussion of worm gears in the February issue. To read the first installment in this series go to the December issue at www. gearsolutions.com.

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

JANUARY 2012

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HOTSEAT

jackTitus

Director of process and developmental engineering, AFC-Holcroft

Catalytic Gas Nitriding, a process available in Russia for decades that has migrated to the United States, stands to alter our thinking of nitriding as a case hardening process. Heat treating is often a conflict in terms: Heat, then cool as fast as possible while trying to reduce distortion. Case hardening steel is all about diffusing carbon into the face-centered cubic iron lattice (FCC) of austenite and quenching into a heat transfer fluid; air, nitrogen, helium, oil, water or salt. Below the A1 critical temperature of 1333°F (723°C) iron transforms back to the body-centered cubic lattice (BCC). If transformation occurs slowly allowing carbon to precipitate out of the BCC lattice as pearlite or cementite (iron carbide, Fe3C) the BCC lattice remains, relatively speaking, in cubic form. Quench steel fast enough to below the A1 temperature and trap carbon within the BCC lattice, martensite the body-centered tetragonal (BCT) lattice, a stressed form of the BCC lattice forms. And that stress causes a deformation or strain of the part shape. If heat transfer could be controlled to cool all areas of a part equally only uniform growth of the part dimension will result, but that won’t happen; it’s impossible for there is no heat transfer mechanism or method that can remove heat that uniformly. Consequently we have specifications that allow distortion to occur within limits that will result in drivetrain operation that’s just… well, good enough. Staying within those limits is expensive, so manufacturing engineers and heat treaters must compromise on the most cost effective heat treat process. So where does nitriding fit as a case hardening option? Where gears are involved, today’s nitriding technology has a very limited application because, for one, its effective case depth (ECD) 50 HRC (Vickers 513) is too shallow to support the loads of many drivetrain applications. Nitriding can achieve a surface hardness of 60 to 69 HRC in suitable alloys, and 30 to 40 and higher HRC in the core, again in the appropriate alloy. Why is the ECD important? In practical terms, in my view it represents the threshold between pure hardness and toughness. We all know that gear teeth must have a ductile core to absorb the impact induced as teeth engage while the hard surface resists sliding wear and the intense pressure created as loads increase. Ever wonder why many gear heat treat specifications allow retained austenite levels of 15 percent or more? I believe this phenomenon is partially explained in the paper “Strain Partitioning & Mechanical Stability of Retained Austenite,” May 26, 2010, by Dong-Woo Suh, et al. Sometimes there’s a certain amount of wear-in required in carburized gear trains, and retained austenite acts as a cushion of sorts providing a customized contact morphology that very likely reduces noise. Nitriding

About the author: Jack Titus can be reached at (248) 668-4040 or jtitus@afc-holcroft.com. Go online to [www.afc-holcroft.com] or [www.ald-holcroft.com].

lacks this mechanism. It doesn’t need it since distortion is so minimal that noise is not as much of an issue. Nitriding’s second problem, besides a shallower case depth, is the white layer. Most drivetrain applications require the white layer to be ground off, or better yet not allowed to form in the first place; thus the importance in the controlling the nitrogen potential. Granted, in some gear applications where FNC (ferritic nitrocarburizing) is employed an epsilon white layer is intentionally formed, but in those instances the steel’s core hardness must be high enough to support the high tooth loading. If not you’d have the equivalent of a donut covered with aluminum foil. What’s old is new again, though. Catalytic Gas Nitriding (CGN) is a process available in Russia for decades that has migrated to the U.S. and stands to alter our thinking of nitriding as a case hardening process. It’s well known that in the right hands plasma nitriding can provide better white layer control and faster case development than traditional gas nitriding. It’s also no secret about the degree of difficulty encountered when higher production is required: i.e. special racking, avoiding parts touching each other, and those nasty hole-discharge-prone holes that must be plugged. Traditional gas nitriding attempts to control the development of the white layer by adjusting the decomposition or disassociation of ammonia into atomic nitrogen and hydrogen and diluting ammonia. Decomposition is determined by analyzing hydrogen to calculate the nitrogen potential: Np = p(NH3) / p(H2)3/2. Another method involves dissolving residual ammonia in a water burette leaving hydrogen as a percentage of the whole. Both methods are combined with the two-stage or Floe process. This technique consists of nitriding to develop a compound layer in the first step and initiates diffusion of nitrogen into the steel at about 925°F (496°C). The second step requires a higher temperature usually around 1025°F (552°C) plus or minus with a lower nitriding potential allowing nitrogen to diffuse faster and reduce the white layer thickness. CGN eliminates the need for the two-stage process and substantially improves the ability to control the white layer and its composition. Nitrogen potentials from 3-11 percent can be recipe set and controlled repeatedly regardless of the load make-up and without a thought to part placement. One (N) potential set point is used throughout the process, about 3 percent to produce the diffusion zone without a white layer, and if a compound layer is required it too can be recipe set at higher (N) potentials. No hydrogen analysis is required. More details next month!

gearsolutions.com

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COMPANY profile

Metlab

in terms of both knowledge and capabilities, this company is known for doing whatever it takes to find solutions to its customerâ&#x20AC;&#x2122;s mostcomplex problems. By Russ Willcutt

gearsolutions.com

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Founded just outside of Philadelphia in 1928, Metlab has innovation in its DNA. Originally a manufacturer of aircraft components, it began heat treating as part of the process, developing the “drop bottom” or “gantry” furnace along the way in order to minimize distortion in the delicate aluminum parts it was making. It continued developing its expertise in deep-case carburizing over the years, building huge furnaces to treat large components such as bearings and gears for the mining, industrial, and energy markets, among others, as well as for military applications. It was this history, along with its expansive capabilities, that drew the attention of two heat-treating professionals in 1998. “One of the most attractive things about the company was the facility itself,” according to Mark Podob, vice president of marketing and sales and co-owner along with Jim Conybear, director of operations. “We have a pit furnace that’s 15 feet in diameter and 13 feet deep that we used to nitride the main propulsion gears for the U.S. Navy’s Seawolf class of nuclear submarines, for example. It can accommodate a 43,000-pound gear, along with other very large components, and it can provide a variety of treatments.” Among its long list or services are metal hardening, quenching, and tempering, induction/flame hardening, vacuum heat treating, annealing and protective atmosphere normalizing, carburizing, carbonitriding, nitrocarburizing, boriding/boronzing, cryogenic treatment, and heat treat stress relieving. The company also provides metallurgical consulting—supported by its fully equipped laboratory—and the fabrication of special parts. It can heat treat parts from one pound to 25 tons, and having so many tools in its belt allows Metlab to address its customers most-complex challenges. “We view ourselves as consultative heat treaters,” Conybear says. “For instance, a customer came to us about 10 years ago who was having a problem with the rails in his material handling system. He was using carbon steel, which was only lasting a year, and we suggested that he make them out of tool steel because of its excellent wear characteristics. He ended up asking us to design and manufacture the whole system,

which we did, turning a $20,000 order into one worth around $300,000. But he hasn’t had to replace those rails or even grind them in more than a decade now.” Podob agrees, recalling another project involving a large fabricated gear used in the rolling mill of a steel plant. The manufacturer needed help controlling distortion, so Metlab joined a multi-company team in addressing the problem. “It took us about a year to arrive at our lowest-possible distortion,” he explains, “and not only did it require refining the design of the gear, we also had to change the manufacturing process and sequence, and even develop special fixturing in the heat treatment cycle. This gear had a three-foot face width, a case depth in excess of a quarter of an inch, and when we were done it was round within 30 thousandths. The only downside was that they only need one of those every 10 years or so.”

“We spend a lot of time writing process specifications and making sure the job is done correctly from start to finish. We really pride ourselves on taking that type of approach.” More capabilities were added in 2001 with the acquisition of J.V. Potero, Inc., which specialized in the protective atmosphere heat treating of small to medium size batches, induction hardening, and black oxide finishing of steel parts. The acquisition was part of a careful strategy the two partners have developed. “When Jim and I bought the company, it was primarily focused on these extremely challenging ‘one-off’ projects, and even though we’re both drawn to that type of work we realized that we also need to make payroll,” Podob says with a laugh. “So in recent years we’ve really worked hard to pull in some ongoing contract work, as well.” Still, the two men thrive on identifying solutions to the problems its customers encounter. “We’re basically a job shop going from project to project,” Conybear says, “so you never know what you’ll find when you step out into the production area. What you’ll see one week will be completely replaced by an entirely different range of products next week. And while it’s a challenge to schedule that type of work, we spend a lot of time writing process specifications and making sure the job is done correctly from start to finish. We really pride ourselves on taking that type of approach, and I think it’s something our customers appreciate as well.”

tO Learn MOre: Call (800) 319-7359 or (215) 233-2600. Send e-mail to sales@metlabheattreat.com, or visit online at www.metlabheattreat.com.

GearSolutions_January12.indb 27

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Processing New Gear Steels QuesTek Innovations and Solar Atmospheres explain the manufacturing and processing of a new class of vacuumcarburized gear steels with very high hardenability. By C.P. Kern, Dr. J.A. Wright, Dr. J.T. Sebastian, J.L. Grabowski, D.F. Jordan, and T.M. Jones

GearSolutions_January12.indb 28

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CARBURIZED STEEL GEARS ARE WIDELY USED FOR POWER TRANSMISSION IN ROTORCRAFT, TRANSPORTATION VEHICLES, AGRICULTURAL AND OFF-ROAD EQUIPMENT, INDUSTRIAL ROTATING EQUIPMENT, AND THOUSANDS OF OTHER APPLICATIONS. HISTORICALLY, ALLOYS REQUIRING CARBURIZATION WERE PUT THROUGH AN ATMOSPHERE (GAS) PROCESS. HOWEVER, IN RECENT YEARS, THE ADVANCEMENT OF LOW-PRESSURE (I.E., VACUUM) CARBURIZING HAS LEAD TO CERTAIN APPLICATIONS TO TAKE ADVANTAGE OF REDUCTION IN PROCESS STEPS AND IMPROVEMENTS IN CASE PROFILE UNIFORMITY. A NEW CLASS OF GEAR STEELS, FERRIUM® C61 AND C64, WERE SPECIFICALLY DESIGNED AND DEVELOPED TO MAXIMIZE THE BENEFIT OF VACUUM CARBURIZATION PROCESSES. Ferrium C61 and C64 are highly hardenable,

that allows for the use of higher processing temper-

secondary hardening martensitic steels. The high

atures available in vacuum carburizing to increase

hardenability of these alloys allows for a mild gas

the carbon diffusion and reduce cycle time. The

quench, which can used in vacuum carburizing,

grain pinning dispersion particle also allows for

that promotes uniform martensitic transformation

increased forging temperatures in gear production

throughout the entire component allowing for less

that can extend the life of a forging die. In addi-

distortion and thus reducing the amount of grind-

tion, the alloys use an efficient M 2C carbide that

ing stock removal required. These alloys were also

requires less carbon content than traditional alloys

designed with a grain pinning dispersion particle

that achieve hardening using an epsilon carbide. In

Fig. 1: The “Design Chart” used by QuesTek to design the Ferrium C64 alloy. The hierarchical relationships between processing, structure, properties, and performance are summarized graphically and serve as the template for alloy design. JANUARY 2012

GearSolutions_January12.indb 29

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Fig. 2: Comparison of thermal processing path associated with the carburization, austenitizing, and tempering of 9310 compared to Ferrium gear steels (note: elimination of three thermal processes and associated plating/striping with each process).

Fig. 3: Jominy end-quench comparison of 9310 and Ferrium C61 per ASTM A255.

addition to the manufacturing benefits outlined above, these alloys also have significantly improved core properties that lead to performance advantages compared to conventional gear steels. A comparison of atmosphere and vacuum carburizing addresses some of the advantages and disadvantages of each will be presented. With the advancement of vacuum carburizing processes in recent years, there are a growing number of applications that make the use of vacuum carburizing an effective process-

Fig. 4: Comparison of mechanical properties and thermal stability (via tempering temperature).

ing selection. A framework comparison of a high-performance racing and highperformance aerospace application are used as two examples that can benefit from the use of these new alloys processed via vacuum carburizing.

Design and Overview Ferrium C61TM and C64TM are two new alloys being used or considered for power transmission applications. Both of these

Fig. 5: Process schematic of a typical case-hardened gear.

alloys utilize an efficient nanoscale M 2C carbide strengthening dispersion within

QuesTekâ&#x20AC;&#x2122;s Ferrium C-series alloys are

for oil-quench dies, thus reducing the

a Ni-Co lath martensitic matrix. QuesTek

advanced new gear steels designed for

amount of machining stock required

designed these alloys considering the

significant manufacturing and perfor-

due to distortion. The alloys were also

complex interplay of critical design fac-

mance advantages over conventional

designed to use an efficient strengthen-

tors including: martensitic matrix sta-

aerospace gear steels that can sig-

ing mechanism that requires up to 50

bility (M s temperature); M 2 C carbide

nificantly streamline gear production,

percent less carbon compared to cur-

thermodynamic stability and formation

decreasing lead times and reducing cost.

rent state of the art alloys, therefore

kinetics; matrix cleavage resistance; and

These steels take advantage of vacuum

reducing the carburization time by up

embrittling phase thermodynamic stabil-

carburization thermal processing and

to 50 percent. In addition to the manu-

ity with the use of their suite of compu-

have high-hardenability that allows for

facturing benefits the alloys also have

tational models [1, 2] (fig. 1).

mild-gas quenching, eliminating the need

performance enhancement benefits that

gearsolutions.com

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Fig. 6: Comparison of the reduction in processes required during hardening between atmosphere and vacuum carburizing.

allow for increased power transmis-

after carburization (combination of

sion, reduced weight, and increased

carburizing and austenitizing steps;

thermal

Computationally

fig. 2); can double the efficiency of

designed and developed by QuesTek

a current facility by elimination of

Innovations, under Navy, Army, and

many copper plating and stripping

internal funding, the alloys are com-

operations associated with current

mercially

Latrobe

thermal processing, and eliminate of

Specialty Steel Company located in

the costs and setup time associated

Latrobe, Pennsylvania. Commercial

with custom quench press dies cur-

stability.

available

from

procurement and processing specifi-

rently required.

cation documents, such as Aerospace

â&#x20AC;˘ R eduction of grinding operations and

Materials Specification (AMS), are cur-

costs, smaller excess stock removal

rently in development.

and waste by reducing quench dis-

Carburization Methods

tortion and avoidance of the intergranular oxide formation typical of in

Ferrium C61 and C64 were specifically

pre-oxidation steps of conventional

designed to achieve high hardenabil-

alloys. Due to higher hardenability

ity and use high-temperature, low-

of Ferrium gear steels (fig. 3), a

pressure (i.e., vacuum) carburization

slower gas quench process result-

and gas quenching process methods,

ing in uniform properties and very

permitting significant reductions in

low distortion after heat treating can

manufacturing costs and schedules

be achieved. This can be especially

due to:

beneficial for components with larger cross-section where cooling rates

â&#x20AC;˘ S horter thermal processing times at higher carburizing temperatures (fig. 2);

in the core may be slower.

Increased Forgability

â&#x20AC;˘ E limination of separate hardening

These alloys were designed to be

and oil quenching process steps

worked at higher temperatures com-

JANUARY 2012

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pared to the incumbent alloys. The reason behind this is the increased thermal stability of the grain pinning dispersion used. Where alloys such as X53 typically have grain pinning dispersion particles that go into solution around 1830°F, the particles employed in Ferrium gear steels are stable to 2250°F. This allows an increased forging range by over 300°F. This increase in temperature also allows increased throughput and longer die life.

Greater Core Strength These alloys exhibit core steel tensile strengths (UTS) of 229 ksi or more, which is a 35+ percent increase com-

Fig. 7: Image showing that the amount of distortion is related to the quench rate for a low-alloy steel of 0.25” diameter. Milder quench rates promote uniform cooling, reducing the stress gradient and subsequently distortion.

pared to conventional gear steels and allows significant reductions in part size and weight, particularly where structural components are integrated with gearing into single components.

Greater High Temperature Survivability Ferrium C-series alloys exhibit increased thermal stability compared to AISI 9310 or Pyrowear X53, because they were designed to be tempered at 900°F or 950°F, and thus can withstand service temperatures up to 500°F hotter than AISI 9310 or Pyrowear X53. Increased thermal stability is expected to result in greater ability for a gearbox to survive “oil-out” or low lubricant situations, and endure other high-temperature operating conditions (fig. 4). Additional information about the properties and development status of each alloy can be found in 09FTM14, Design, Development and

Fig. 8: Comparison in the reduction of process steps between atmosphere and vacuum carburizing in both racing and aerospace applications.

Application of New High-Performance Gear Steels.

Atmosphere vs. Vacuum Carburizing

process in certain applications. While

precision applications (where machining

some consider these competing tech-

tolerances are pertinent). There is still a

nologies, they may be considered comple-

broad range of applications in between the

The history of case hardening via car-

mentary as each processes has benefits

above examples where both processes will

burization has been well presented over

given the application involved. Atmosphere

work effectively, but typically is decided

the years. While atmosphere carburization

carburizing is still cost effective for large

by a judgment call or preference on the

still is the predominant processing meth-

batch production and extremely large com-

part of the material and processing or

od used, vacuum carburization has been

ponents, while vacuum carburizing is cost

manufacturing engineer responsible for

starting to make progress as the preferred

effective for lower batch production and

the thermal processing. A summary of

gearsolutions.com

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Fig. 9: Example of ring gear (left) in a highperformance off-road racing application used in 1/-1600 SCORE series.

Fig. 10: Example of transmission gear in a highperformance rotorcraft application.

the advantages and disadvantages of both atmosphere and vacuum carburizing are given below [3, 4].

Atmosphere Carburizing Advantages: • Low capital equipment cost • High volume output • Good experimental process control Disadvantages: • N eed to condition equipment or keep in constant operation • L arge grind stock required on material to remove intergranular oxide layer • L arge case depth variations between flank and root • S afety/fire prevention issues • E nvironmental pollution due to CO and NO x emission

Vacuum Carburizing Advantages: • R eduction in post grinding due to eliminating the presence of inter-granular oxide layer • H igher temperature capabilities (increased carbon diffusion reduces processing time) • M ore uniform case depth between flank and root (also good blind hole penetration)

JANUARY 2012

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• O nly need to operate equipment while

hardening and grinding processes. The

reduce the need for quench dies due to

processing parts (reduced energy

amount of steps contained within each

the more uniform case profile, allowing

consumption)

of these two processes is different for

for more uniform martensitic transfor-

various applications. Two examples in

mation (less stress gradient associated

the racing and aerospace markets will

with phase change from FCC to BCC)

be outlined below to describe the step

and reduce the amount of distortion

reduction and potential time and cost

contained within a component. In addi-

savings.

tion, the use of high hardenable alloys,

• C an use both oil and gas quench medium • Use of inert gasses reduces pollution during out-gas • R educed distortion due to uniform case and the use of gas quench medium

A more detailed breakdown of the

Ferrium C61 and C64, allow for mild gas

hardening process comparison between

quenching that even further reduces the

atmosphere and vacuum carburizing is

distortion caused by non-uniform con-

Disadvantages:

shown in fig. 6. As shown, the advan-

version [5, 6] (fig. 7).

• Higher initial equipment cost

tages of vacuum carburization allow for

Processing of Ferrium C61 and C64

• P art cleanliness can affect diffusion

a combination of carburization and aus-

has also demonstrated that the need for

tenitizing steps, while eliminating the

a pre-oxidation step is not required for

need for a stress relief in between the

activation prior to carburization; instead

of carbon • S maller furnace load capability

processes. In addition, the increased

hydrogen cleaning can be using dur-

A typical gear manufacturing path is

temperature capabilities of vacuum car-

ing the heating stage of carburization/

outlined in fig. 5. From this process you

burization allow for increased diffusion

austenization. The amount of masking

will see that the advantages of vacuum

of carbon, therefore reducing total cycle

operations can also be reduced by the

carburizing are contained within both the

time. The use of vacuum carburizing can

use of vacuum carburizing. In tradi-

Fig. 11: Framework comparison for manufacture of a high-performance racing ring gear using different carburizing techniques and materials. Vacuum carburizing is a lower cost and less processing steps for equivalent performance in 9310. For approximately 40% increase in cost, Ferrium C61 and C64 will offer up to 400% increase in lifetime. 36

gearsolutions.com

GearSolutions_January12.indb 36

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Fig. 12: Distribution of gear production costs for manufacture of a high-performance racing ring gear using different carburization techniques and materials. tional atmosphere carburizing, a stopoff paint or copper plate will need to be applied and removed twice throughout the hardening operation. The number of masking steps can be reduced by 50 percent using vacuum carburization due to the integration of the carburizing and austenitizing steps. This means that a given production line can double its through-put of the same plating line by using vacuum compared to atmosphere carburizing. The gear grinding process also receives benefit from vacuum carburizing compared to atmosphere carburizing. A comparison of the grinding operations for a high-performance racing and aerospace application are outlined in fig. 8. After thermal processing there are three main reasons for material removal: removal of an intergranular oxide layer, removal of any remaining primary carbides due to over-carburization, and removal of any remaining distortion. In a typical racing application where the tolerances have less restrictions and the risk of failure due to primary carbides will not lead to catastrophic loss, the main grinding operation is completed for removal of the inter-granular oxide layer. When processing via vacuum carburizing, this inter-granular oxide layer is no longer present and can typically eliminate grinding operation altogether.

JANUARY 2012

0112_QuesTek.indd 37

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In a typical aerospace application where the tolerances are

(vertically integrated). One such example is a gear used in a

very restrictive and the risk of failure due to primary carbides

rotorcraft transmission box [7], [8]. A typical batch size for

may lead to catastrophic failure, the grinding operations con-

this would be on the order of one-hundred components. The

sider all three factors mentioned above. In atmosphere carbur-

process would start with procurement of bar stock from a mill

izing there is the removal of the inter-granular oxide, removal

or third party vendor. A starting blank would then be cut from

of a set amount of stock that has historically shown primary

the bar stock, followed by hobbing of gear teeth. The gears

carbides, and removal of any additional stock that is due to

will then under-go a hardening process that consists of car-

distortion. When processing via vacuum carburizing, the inter-

burization, austenitizing, quenching, cryogenic treatment, and

granular oxide layer is eliminated and the amount of material

temper (in the case of atmosphere carburizing, a machining

removal due to distortion is reduced due to uniform case con-

step may be inserted after the carburization and prior to the

version. The use of Ferrium C61 and C64 further reduce the

austenitizing step). Throughout the hardening process there

amount of material required to remove distortion due to the

are also masking operations that use copper plating that is

high hardenability that allows for even milder quenching, while

removed/stripped after processing. Gears are then ground to

still achieving full martensitic conversion.

remove primary carbides from the surface and to eliminate the

Example Applications This paper will focus on manufacture of a gear for high performance racing and aerospace applications. These two applica-

distortion from the quenching process during hardening. The gears are then inspected prior to installation in the gearbox (fig. 10).

tions were selected based on the high performance require-

Skeleton/Framework

ments and the precision manufacturing process that would

This section will provide a framework comparison for both

receive the most benefit from adoption of a new class of higher

the racing and aerospace applications outlined above. The

strength and toughness gear steels. In each instance, a step

framework will have some slight variations in the processing

by step manufacturing comparison will be made compared to

as outlined in sections above and the major cost difference

9310, a standard baseline for these high performance appli-

between the two applications is driven by the machining toler-

cations, using both the atmosphere and vacuum hardening

ances required.

processes.

Racing Application

A detailed analysis for the racing application that was discussed above is shown in fig. 11. The processing steps outlined are based on the prior discussion related to advantages

The high-performance racing application will focus on small

of vacuum carburizing and the use of Ferrium C61 and C64.

lot production that is manufactured through a supply chain of

The framework is based on all work being completed by out-

vendors. One such example is a ring gear used in the transaxle

side vendors using a production lot size of 25 components.

of off-road racing vehicles. A typical batch size for this would

The cost associated with the component production is based

be on the order of twenty-five components. The process would

on the average of a broader range for each processing step

start with procurement of bar stock from a mill or third party

and can be adjusted by each individual based on their internal

vendor. Then a forging house would cut blanks and ring-roll

costs or their preferred vendors. The capital cost of equipment

to the desired shape, annealed, and ground/grit blasted. The

is built into the unit cost by each individual vendor and is not

forging blank would then be sent to a machining house to cut

considered a factor for this analysis. The costs represented in

the gear teeth. The gears will then under-go a hardening pro-

the table are normalized to represent the cost for production

cess that consists of carburization, austenitizing, quenching,

of a single component.

cryogenic treatment, and temper (in the case of atmosphere

When comparing the use of atmosphere and vacuum carbur-

carburizing, a machining step may be inserted after the car-

izing processing for that of the baseline alloy (9310), there is

burization and prior to the austenitizing step). Throughout the

approximately a 10 percent reduction in the overall number of

hardening process there may be several steps of masking and

processing steps (translates to reduction in delivery time) and

cleaning using paint. Lastly, gears are then shipped back to

a reduction in cost can be achieved while receiving the same

the machining house for lapping prior to assembly in the final

performance. In the case of both Ferrium C61 and C64, there

application (fig. 9).

is approximately a 50 percent reduction in the overall number

Aerospace Application

of processing steps, but an increase in cost of approximately 40 percent. The increase in cost for this application is largely

The high-performance aerospace application will focus on large

driven by the increase in material costs. However, results from

lot production that is primarily manufactured at the original

components in service have demonstrated up to a 400 per-

equipment manufacturer (OEM) using in-house equipment

cent increase in life cycle. Therefore, there is a tradeoff to be

gearsolutions.com

GearSolutions_January12.indb 38

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Fig. 13: Framework comparison for manufacture of a high-performance aerospace gear using different carburizing techniques and materials. Vacuum carburizing is a lower cost and less processing steps for equivalent performance in 9310. For an equivalent cost, Ferrium C61 and C64 will offer increased performance in the form of weight reduction, increase life cycle, or a combination thereof. made for upfront cost compared to long-term costs associated

by 50 percent allows for an increase in production on a given line

the anticipated life of the component when selecting the material

or the ability to reduce the number of shifts required for a given

for use. With selection of either material, vacuum carburizing is

line depending on the current production demand. Another advan-

a more time- and cost-effective method for processing of gears

tage to vacuum carburizing is that the components are â&#x20AC;&#x153;cool to

(fig. 12).

the touchâ&#x20AC;? throughout the carburization/hardening process. The

A detailed analysis for the aerospace application that was discussed above is shown in fig. 13. The processing steps out-

parts are loaded and removed from the furnace at or near room temperature, reducing the risk of burn accidents or fires.

lined are based on the prior discussion related to advantages of

When comparing the use of atmosphere and vacuum carbur-

vacuum carburizing and the use of Ferrium C61 and C64. The

izing processing for that of the baseline alloy (9310), there is

framework is based on the majority of work being completed

approximately a 15-percent reduction in the overall number of

internally at an OEMâ&#x20AC;&#x2122;s facility using a production lot size of 100

processing steps (translates to reduction in delivery time) and

components. The cost associated with the component production

a reduction in cost can be achieved while receiving the same

is based on the average of a broader range for each processing

performance (fig. 14). In the case of both Ferrium C61 and C64,

step and can be adjusted by each OEM to match their internal

there is approximately a 50-percent reduction in the overall

costs or their preferred vendors. The capital cost of equipment is

number of processing steps, while only showing an increase in

estimated within the unit cost shown below, but there are several

cost of approximately 5 percent. With the majority of the costs

advantages and cost savings that should be discussed from an

associated with precision machining to meet the tolerances

OEM processing standpoint. The costs represented in the table

required for aerospace applications, the cost of the material

are normalized to represent the cost for production of a single

does not have nearly as great an impact in the overall compo-

component.

nent cost. Therefore, the ability to increase performance at the

There are several advantages to using the vacuum carburizing process for OEMs. The ability to reduce the copper plating steps

same operating cost can be achieved by the use of Ferrium C61 and C64.

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Fig. 14: Distribution of gear production costs for manufacture of a high-performance aerospace gear using different carburization techniques and materials.

Conclusions

References:

Ferrium C61 and C64 gear steels have been designed and

1) 0 9FTM14, Design, Development and Application of New

developed to make use of advantages offered by that of the

High-Performance Gear Steels.

vacuum carburizing process. The key design advantages that

2) K uehmann, C.J., and Olson, G.B., Computational Materials

results in manufacturing benefits are based on the high hard-

Design and Engineering, Materials Science and Technology,

enability, efficient M 2C strengthening carbide, and MC grain

2009, Vol. 25, No. 4, pp 472-487.

pinning dispersion. The high hardenability allows for complete and uniform transformation of the case and core with the use of milder gas quenches, resulting in less distortion and grinding stock removal. The efficient M 2C strengthening carbide

3) 0 2FTM07, Selecting the Best Carburizing Method for Heat Treatment of Gears. 4) O tto, F.J., Herring, D.H., Gear Heat Treatment: Part I, Heat Treating Progress, June 2002.

allows for a reduction in the amount of carbon necessary for

5) Tom Croucher & Associates, Polymer (Glycol) Quenchants.

the same strengthening response, resulting in shorten car-

6) P owell, J.A., Aronov, M.A., IntensiQuenchSM Process Theory

burization times. The MC grain pinning dispersion allows for

and Applications, April 2002.

increase thermal processing temperatures in both forging and

7) H enry, Z.S., Bell Helicopter Advanced Rotorcraft Transmission

carburizing processes. The ability to increase the forging tem-

(ART) Program, NASA Contractor Report 195479, June

perature reduces the flow stress of the material that allows for

1995.

increased throughput and longer die life for forgings. The ability

8) K ish, J.G., Sikorsky Aircraft Advanced Rotorcraft Transmission

to carburize at higher temperatures allows for an increase in

(ART) Program, NASA Contractor Report 191079, March

carbon mobility that also contributes to the reduction in carbur-

1993.

ization times and allows for the combination of the carburizing and austenitizing processes into a single step. In addition to the manufacturing benefits of both alloys, performance benefits are achieved in the form of an increase in over 30 percent in mechanical properties and over 500째F in thermal stability of the microstructure. Ferrium C61 and C64 can be cost effective solutions based on a framework analysis of a high-performance racing and a high-performance aerospace application presented above. In applications where precision machining is not a main factor, the material cost typically drives the overall component cost. However, while the racing application provided had an increase in cost of 40 percent, there is up to a 400 percent increase in life cycle based on the increase performance of Ferrium C61 and C64. In applications where precisionmachining is a main factor and typically drives the overall components cost, the increase in material cost is negligible. In these applications, the performance enhancements offered by Ferrium C61 and C64

about The authors: About the authors: C.P. Kern, Dr. J.A. Wright, Dr. J.T. Sebastian, and J.L. Grabowski are with QuesTek Innovations LLC [www.questek.com]. D.F. Jordan and T.M. Jones are with Solar Atmospheres [www.solaratm.com]. The authors would like to thank the Department of Defense, specifically the U.S. Navy, U.S. Army, and Battelle/NASA, and OEM partners, specifically Boeing, Bell Helicopter, Sikorsky, General Motors, and Tata Motors, and manufacturers and end-users, specifically High Performance Gear and Boyer Racing Team, for continued evaluation and implementation. Printed with permission of the copyright holder, the American Gear Manufacturers Association, 1001 N. Fairfax Street, 5th Floor, Alexandria, Virginia 22314. Statements presented in this paper are those of the authors and may not represent the position or opinion of the American Gear Manufacturers Association.

can be had at a similar cost to that of a lower grade alloy.

JANUARY 2012

GearSolutions_January12.indb 41

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Eliminating Gear Whine Advanced simulation techniques from Romax Technology eliminate gear whine problems in automatic transmissions. By Dr. Michael F. Platten and Melanie Fitton-Hayward

The intrusive noise known as gear whine is caused by vibrations generated by gears as they mesh as a result of imperfections caused by design, loading, temperature effects, and manufacturing variations. Reducing gear whine noise to an acceptable level is a big challenge, especially for complex gearboxes like the modern planetary automatic transmission. Advanced design, simulation, and analysis tools like RomaxDesigner give engineers the ability to quickly and accurately identify problems, find the root cause, and propose realistic solutions within the allowable design constraints. With such a tool, existing designs can be optimized to remove noise problems, and new designs can be created that are known to be problem-free even before any metal is cut. Here we develop a process for optimizing an existing design to reduce a noise problem and show how it works with a real-world example.

Gear whine does not have to be

tooth surface on a microscopic

consider that any micro-geometry

loud to be a problem. It is by nature

level. These “micro-geometry” mod-

changes you make will also impact

a tonal noise, which is annoying to

ifications can be tailored to reduce

the durability and efficiency perfor-

drivers and passengers because

TE, but to know what changes to

mance of the gearbox. It is no good

it cuts through other noises in the

make you need to understand how

having a quiet gearbox that breaks

vehicle interior. Perfect gears in

the gear teeth are behaving at a

after 50,000 km.

a perfect operating environment

microscopic level. You also need to

A quick glance at fig. 1 will tell

produce no noise, but unfortunately we do not live in a perfect world. The real world is one of manufacturing and assembly tolerances, and components that deflect under the loads we put through them. The difference between the smooth transfer of motion by perfect gears and what you actually get in practice is called “transmission error,” or “TE.” This is the true source of gear whine noise. TE causes a vibration at the gear mesh which is transmitted through the internal gearbox components to the housing, where it is radiated directly as noise or transferred through the chassis in the form of vibrations to be radiated as noise elsewhere. Although not the sole method of controlling gear whine, reduction of the noise at the source by reducing TE is clearly a good idea. The usual way of adjusting TE is through making changes to the

Fig. 1: RomaxDesigner model of a six-speed automatic transaxle gearbox. JANUARY 2012

Fig. 2: A process for identifying and resolving a gear whine noise problem in an automatic transmission. you that a modern automatic transmission

make design decisions based on them.

cumbersome model that takes a lot of com-

is a complex beast, with many gears mesh-

When this is combined with fast computa-

puter time to run, but we do need to include

ing simultaneously. These complexities

tional performance it becomes an enabler

detail where it is important. For example

make it difficult to predict the gear mesh-

for all kinds of useful analysis and optimiza-

we need a very detailed description of the

ing behavior and to identify the optimal

tion methods that rely on repeated simula-

gear geometry and a detailed model of gear

micro-geometry modifications necessary.

tion of subtly different designs, as we shall

tooth contact, but we only need to consider

The only way this can be achieved is by con-

see later.

the simulation of brakes and clutches on a

sidering the gears within the context of the

concept level. We also need to include the

complete transmission. The effects of and

Simulation Challenges

interactions between all these gears mean

Optimizing the design of multi-mesh plan-

whether in the vehicle or on the test bench

that a system-level simulation such as that

etary gearboxes presents a number of prob-

so that our model represents what we are

provided by RomaxDesigner from Romax

lems when compared to simpler manual

actually testing.

Technology (a quick and accurate virtual

transmission designs, which means that

product development tool with the capabil-

specific methods have had to be developed

ity to simulate, analyze and optimize the

by Romax Technology to deal with auto-

Load Sharing and Misalignment

NVH, durability and efficiency performance

matic gearboxes.

Automatic transmissions achieve their high

of the most intricate designs) is a necessary tool in the process of making these

Complexity of Design

gearboxes quiet.

effect of the gearbox boundary conditions

power density by splitting the transfer of torque through several planet gears

A planetary automatic gearbox is complex

simultaneously. System deflections due to

Quick and accurate simulation of these

with many components. To simulate it we

internal loads, manufacturing errors and

complex behaviors is the key to an improved

need to represent that complexity but only

external radial loads (such as gravity and

product. Obviously accuracy is important;

to a level of detail that is necessary to give

those from the transfer gear shown in fig. 1)

we need to be able to trust the results and

us the results we needâ&#x20AC;&#x201D;we do not want a

destroy the symmetry of the planetary sys-

gearsolutions.com

arrangement a planet gear is connected to at least two other gears. The misalignment at one gear mesh has an influence on the misalignment at other gear meshes because they are all connected by the same gear. What this means practically is that the detailed analysis of these gear meshes which is required to correctly predict TE must simulate the effect of all gear meshes simultaneously (the case study on pg. 48 has 9 meshes). In addition the simulation must include the effects of the

Fig. 3: Comparison between measured baseline housing vibration, simulated baseline housing vibration, and simulated optimized housing vibration.

variation in torque and misalignment as the components rotate. In RomaxDesigner this is achieved by performing an iterative static analysis of

tem and result in unequal sharing of that

manufacturing and assembly tolerances.

the entire gearbox at several different car-

torque between the planets. To make mat-

The knock-on effect of this is that different

rier rotation positions to build up a com-

ters worse, this inequality varies as the car-

torques in each gear mesh means differ-

plete profile of the gear contact behavior

rier rotates relative to the sun and ring due

ent misalignments in each gear mesh and

considering all of the above complications.

to changes in the stiffness of the carrier,

these also vary as the carrier rotates. A

This is a relatively quick process due to

the effects of gravity and slight variations

final complication is interactions between

the optimized algorithms used, giving an

in planet pin position within the allowable

different gear meshes. In a planetary gear

answer in a matter of seconds.

JANUARY 2012

Gear Mesh Phasing

of how good our noise performance will be for an automatic trans-

When we look at gear whine caused by a simple gear pair, we can

mission, as there is no simple relationship between individual

say that the resulting gear whine noise is directly proportional to

mesh TEs and the resulting noise in the vehicle. Instead we

the TE. This means that if we discover that we need to reduce

must use the vibration of the transmission housing as a mea-

the noise by 50 percent then we know that we have to reduce the

sure of success or failure and that means we need a dynamic

TE by 50 percent. As with everything else, the planetary gearbox

model of our gearbox.

does not behave quite so nicely. In the automatic transmission we have many meshes active at

Dynamic Response

once, each producing their own TE all at the same time and all

Predicting vibration response behavior of a gearbox requires

at the same frequency. However the relative phases of these TE

two things: knowledge of the excitationâ&#x20AC;&#x201D;in our case, the TE,

signals are not always the same. The combined noise effect of all

which we know our methods can accurately predictâ&#x20AC;&#x201D;and also

the TE signals together depends on this phasing. In some cases

a dynamic model of the complete transmission system. We can

the signals add together and reinforce the resulting vibrations

apply the predicted TE at each mesh (including the phasing) in

(and hence the sound heard by the driver); in others the signals

the dynamic model and predict the response at any location

cancel each other out and the vibration in a particular direction

on the housing. These can be compared directly with vibration

is reduced. These phase differences are generated at two levels:

measurements on the real gearbox. RomaxDesigner includes

the majority of this phasing is determined by the number of teeth

the capability to automatically generate a dynamic model and

on the gears, the number and positioning of the planet gears

calculate the response.

and whether the gearbox as a whole is more sensitive to lateral

So there are many difficulties associated with the simulation

or torsional dynamic forces. Small changes to the phasing are

of gear whine in planetary automatic gearboxes but we have

also caused by the micro-geometry design of the teeth. Paying

been able to implement methods to cope with these within the

attention to this phasing early in the design process is critical to

RomaxDesigner virtual product development environment. Next

a good gearbox design.

we will see how these methods can be put to use in a gear whine

What this implies is that we cannot simply use TE as a measure

gearsolutions.com

troubleshooting process.

changes such as changing gearbox layout, tooth numbers, or number of planets. In these cases refining micro-geometry is often considered the only approach. An example optimization process based only on micro-geometry modifications is discussed here and illustrated with a real world case study later. The overall troubleshooting process is shown in fig. 2. The first step is to identify the conditions under which the problem occurs. This is done by subjective evaluation in the vehicle. This is backed up by a quantitative measurement of noise and vibration both in the vehicle and on a test bench. The results of these tests form the baseline results against which the noise and vibration of the new design can be compared. If the test bench results show the same symptoms as the in-vehicle results, then all further simulation and testing can be performed in the more controlled environment of the

Fig. 4: Components of the rear planetary gear set in the six-speed transmission.

Troubleshooting Problems

laboratory. Analysis of these test results also yields information on which planetary gear set is causing the problem. The next step is to create the RomaxDesigner model of the transmission. This model should represent as closely as possible the actual transmission tested and the boundary conditions should

As well as upfront design of new products, another common reason

represent those of the test (in-vehicle or test bench). Typically this

for optimizing a design for NVH is when an existing design is put

means that the micro-geometry of the gearbox being tested should

into a new application (a new vehicle model or paired with a new

be measured and the exact micro-geometry used in the model.

engine for example) and whine noise is found to be a problem.

Critical dimensions such as planet pin positions, housing bearing

In a situation like this, there is very little scope for major design

bore locations and axial and radial clearances of critical compo-

JANUARY 2012

pattern, but the housing vibration; so with the optimization phase complete, the final steps are to confirm that the new simulated vibration response for the optimized design is reduced to an acceptable level. This is then confirmed in the real gearbox by a oneoff prototype test before production of the transmission with the revised gear design can be resumed.

Case Study In an SAE paper, Hyundai described how they used these methods to address a gear

Fig. 5: Comparison of gearbox radiated noise before and after optimization.

whine problem, in a six-speed planetary automatic transaxle gearbox, which was

nents should also be measured to ensure

upon in fig. 2. The heart of the process is a

identified by subjective testing. Subsequent

that they conform to the design specifica-

parametric sensitivity study where the most

quantitative testing identified increased

tion. Ideally these measurements should be

important parameters are varied and their

noise levels in the medium to high torque

performed on a number of gearboxes from

effect on the contact pattern and TE identi-

range (60 Nm-200 Nm), at engine speeds

the production line to check manufactur-

fied. In the example shown we are only con-

of 900 rpm-1300 rpm.

ing variability. If any components are out

sidering micro-geometry parameters, but

A complete gearbox model with detailed

of tolerance (especially micro-geometry)

other parameters could be assessed in the

shafts, bearings, gears and housing was

then these manufacturing issues should

same way. Overall we are looking to reduce

created (fig. 1). Radial clearances at the

be addressed first before any further inves-

the TE of individual meshes and the com-

bushes and internal clearances of the

tigation continues. In terms of boundary

bined TE of all meshes together while still

bearings were calculated from the design

conditions, we need to simulate, at least

maintaining a centralized contact pattern

tolerance, accounting for thermal expansion

approximately, the upstream and down-

and acceptable surface stress to ensure

under operating conditions. Details of the

stream rotary inertia and torsional stiffness

durability is not compromised.

actual test gearbox (clearances and mea-

as well as the support conditions for the

The sensitivity analysis is first performed

sured micro-geometry) were used in the

on the planet-ring gear meshes and the

model for maximum simulation accuracy.

The predictions from the model should

revised micro-geometry is applied to the

Three load cases were used for the testing

be compared with the baseline test results

gears in the model (usually this micro-

and analysis to cover the operating torque

to confirm that the model is recreating the

geometry is applied only to the planet

range. RomaxDesigner was then used to

symptoms of the original problem. This

gear as precise hard or soft finishing of

predict the vibration on the gearbox hous-

means we can be confident that any design

an internal gear is difficult in a mass pro-

ing, the results of which compared well

changes we make in the virtual world will

duction environment). The same process

with measurements from the baseline test

have the same effect in the real world and

is then performed on the sun-planet gear

(fig. 3).

we can now proceed to the optimization

meshes and the revised micro-geometry is

Analysis of the noise measurements

phase.

again applied. Now remember that one of

showed that the rear planetary system

It is important that the loading condi-

the difficulties with simulating gear whine

was the source of the gear whine noise

tions we choose for the optimization do not

in planetary gears is that changes made to

(fig. 4). This gear set is a reversing plan-

just include those conditions where there

one gear mesh affect the performance of all

etary arrangement comprising a sun gear,

is a gear whine problem. We also need to

gear meshes. This means that we have now

three inner and outer planet gears and a

consider those conditions where the noise

have to go back and repeat the analysis on

ring gear. The micro-geometry optimization

is not perceived to be annoying. This is to

the ring-planet meshes again to see if these

process described above was applied to

ensure that any design changes we make

need revising. Theoretically we could repeat

the gear set and a revised micro-geometry

do not have a detrimental effect and we

this iterative loop until perfect convergence

design was generated. Figure 3 shows

avoid the possibility of solving one problem

was achieved, however in practice, one

a comparison of the predicted vibration

but causing another.

iteration is usually sufficient.

response at one location for the baseline

gearbox housing.

The details of the optimization phase of

Of course our target for quantifying noise

and optimized design. There is a clear and

the troubleshooting process are expanded

performance is not the TE and the contact

significant improvement predicted due to

gearsolutions.com

the recommended micro-geometry design

SAE Paper 2011-01-1553.

4) Parker, R G. “A Physical Explanation

changes. As a final proof of the validity

2) Pears, J et al. “An Analytical Method

for the Effectiveness of Planet Phasing

of the optimized design, prototype gears

to Reduce Gear Whine Noise, Including

to Suppress Planetary Gear Vibration,”

were manufactured and installed in the

Validation with Test Data,” SAE Paper

transmission. The noise and vibration of

2007-01-2241.

about The authors:

the improved transmission was measured

3) Pears, J et al. “Predicting Variation in

on the test bench, and the results in fig.

the NVH Characteristics of an Automatic

5 show a reduction of 6dB in the radiated

Transmission using a Detailed Parametric

noise in the problematic speed range and

Modeling Approach,” 2007-01-2234.

Dr. Michael F. Platten and Melanie Fitton-Hayward are with Romax Technology. Visit online at www.romaxtech.com.

the required noise target was met.

Conclusion Noise problems with complex machinery are always difficult to solve and gear whine in automatic transmissions is no exception. The methods demonstrated here clearly show that it can be done quickly and reliably provided the right tools are available. The key to success is to have the capability to model the complete transmission with sufficient detail and to account for the interactions between all components simultaneously. Combining this with fast computation times makes parametric design optimization a practical reality. The case study presented here shows that these are not just hollow claims. To achieve a 6dB reduction in radiated noise from a gearbox while being restricted to only making changes to gear micro-geometry is a considerable achievement in a mass production environment. Giving engineers tools like RomaxDesigner leads to improved product quality with reduced development times and costs not only when troubleshooting existing designs but also when creating a new gearbox from scratch. Clearly, designing out noise problems on the computer is faster and cheaper than waiting until the prototyping phase and in the case of a new product it usually leads to a better design rather than one that is compromised by remedial changes put in place to eliminate problems which are identified later on in the development process.

Additional Reading: 1) Shin, W et al. “6 Speed Automatic Transmission

Vibration

Magnitude

Prediction and Whine Noise Improvement through Transmission System Modeling,”

JANUARY 2012

Gearing Up for Efficiency Power losses and inertia matching affect the efficiency of linear drives, slowing motion and increasing unnecessary wear. Wittenstein provides an in-depth examination. By Miriam Metcalfe

GearSolutions_January12.indb 50

12/20/11 2:32:30 PM

THE OPERATING EFFICIENCY OF LINEAR DRIVES IS OF GROWING CONCERN TO MACHINE DESIGNERS. HERE’S A LOOK AT THREE COMMON LINEAR ACTUATORS—LINEAR INDUCTION MOTORS, ROLLED AND GROUND BALL SCREWS, AND RACK AND PINIONS—AND HOW THEY IMPACT A MACHINE'S OVERALL EFFICIENCY.

bALL sCrews BALL SCREWS AND LEAD SCREWS HAVE BEEN AROUND FOR YEARS AND ARE USED IN ALL TYPES OF INDUSTRIAL APPLICATIONS. AMONG THEIR ADVANTAGES OVER OTHER LINEAR DRIVES, BALL SCREWS ARE ECONOMICAL FOR SHORT TRAVEL LENGTHS, SO THEY’RE OFTEN PREFERRED FOR APPLICATIONS SUCH AS Z-AXIS DRIVES. AND LEAD SCREWS AND HIGH-LEAD BALL SCREWS CAN BE NON-BACK DRIVABLE, MEANING THAT A VERTICAL-AXIS LOAD WILL LOCK IN PLACE AND NOT FALL IF POWER FAILS. ON THE DOWNSIDE, A BALL SCREW CAN BE TREATED AS A LARGE SPRING SENSI-

TIVE TO JERK (CHANGE IN ACCELERATION) AND TO IMPACT LOADS THAT CAN CAUSE DAMAGE AND HARM PERFORMANCE. THE DESIGN ALSO LIMITS ACCELERATION AND DECELERATION CAPABILITIES AND THE MAXIMUM OUTPUT FORCE. Maximum length is another limitation. Ball

rates and peak speeds. It also saves time when

screws mount to a structure at both ends, as there

motion frequently changes direction. Brushless

is really no good support mechanism anywhere

linear motors run quietly and the drive systems

else. So as travel length increases, unsupported

typically have long lives.

length grows, the screw sags, and that hurts per-

On the downside, despite improvements linear

formance. Maximum axis length is typically around

motors are still rather inefficient, and energy con-

six meters. It also means linear stiffness is not

sumption is up to five times that of similarly rated

constant but depends on the nut position, which

rack-and-pinion actuators. Higher energy demands

can create headaches in dynamic applications.

may mean higher up-front infrastructure invest-

Eliminating lost motion or backlash in ball screws

ments, as for high-power lines, transformers, and

usually requires preloading, incurring more fric-

electrical drives. And linear motors generate a

tion, power loss, and potential for abrasion.

lot of heat and often need a secondary cooling

By design, a ball screw has a series of ball bear-

system, which adds to cost and complexity and

ings that travel and recirculate through the nut and

further hurts overall system efficiency. Heat gen-

screw, lubricating the balls and evenly distributing

eration can be extreme in low-speed/high-force

load, friction, and wear. However, it can make the

operations, such as drilling.

screws noisy. Shortstroke applications prevent

Because of their direct-drive nature, linear

complete recirculation of the balls. In such cases,

motors cannot take advantage of gear reduction.

dynamic loads must be derated.

Gearboxes are commonly used to match a rotary

LiNeAr MOTOrs

motor’s speed and torque to the load. With a linear motor, that's not possible and it sometimes leads

Linear motors gained wide use in the 1980s with

to a less efficient system. From a closed-loop

rapid technical advance and the introduction of

control standpoint, oscillations or resonances can

many innovative products, though the pace of

result if external loads induce position deviations.

development has tapered off of late. A prime ben-

Without the reduction in inertia and damping inher-

efit is the moving carriage of a linear motor typi-

ent in a mechanical system, controls issues may

cally has low mass, permitting high acceleration

surface at the work piece.

JANUARY 2012

GearSolutions_January12.indb 51

12/20/11 2:32:30 PM

investment and energy costs against performance advantages and machine productivity. In some cases, for instance, linear motors cannot reach top speed if acceleration and deceleration distances exceed the total travel distance. This can make the linear motor's technical advantages a moot point.

Rack and Pinion Rack and pinion drives have been around for centuries, but recent developments in electronic boosted overall performance and energy efficiency. Advantages include long-term, backlash-free operation and unlimited travel length. In fact, a significant benefit over other designs is lower costs over long travel lengths. Helical gearing gives smooth engagement of teeth and quiet operation. Smooth running also helps

Fig. 1: Horizontal drive.

ensure good part quality and surface finish, for instance, when machining tight-tolerance parts. For high-precision systems,

Among other considerations, contamination from metal chips, particles, and even small parts can be a problem due to

single-pitch error between helical teeth can be around 3 μm, and cumulative pitch error only 12 μm/500 mm.

strong magnetic attraction if the linear motor isn’t protected.

Rather than connecting the drive directly to the workpiece,

And with rack-and-pinion and ball screw systems, brakes can

the mechanical transmission elements let engineers vary gear

be built into the back of a standard servomotor. Linear motors,

ratios and pinion size, and add damping that can eliminate

on the other hand, require an add-on secondary brake that’s

closed-loop instabilities. In essence, it gives designers an

typically more expensive.

extra element to tune the system and optimize performance

Engineers should weigh a linear motor’s potentially higher

and efficiency. On the downside, the rack must be kept clean

gearsolutions.com

GearSolutions_January12.indb 52

12/20/11 2:32:32 PM

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GearSolutions_January12.indb 53

12/20/11 2:32:37 PM

and lubricated, and the lube can splash

tasks, torque requirements depend on

at high speeds.

the entire mass reacting in the drive

Rack and pinion actuators often have

train, so designers must compare load

acceleration rates and peak speeds

inertia to motor inertia. With J M = motor

nearly as good as those of linear

inertia, J L = load inertia, and i = gear

motors. In many cases, the machine

reduction ratio, the necessary moment

frame and structure—not the actua-

for a given acceleration depends directly

tor—limit peak speeds from rack-and

on the sum of the moments of inertia,

pinion and linear-motor systems. Ball screws tend to have somewhat lower

J T = J L + i2 J M.

peak speeds and accelerations.

The Impact of Inertia

The coupling factor λ, sometimes described as the inertia match or mismatch, is a correlation of the external

In general, linear motors have over-

moments of inertia to the moment of

all efficiency as high as 85 percent,

inertia of the motor.

Fig. 2: Drivetrain efficiency.

though some are considerably lower. Ball screws, depending whether or not

λ = J L /( i2 J M );

preloaded, can have efficiencies up to

J M = J L /( i2 λ);

90 percent. Rack and pinion systems

J T = J L + J L / λ = J L (1 + 1 / λ).

can push efficiency to 97 percent. Mechanical linear-motion systems

With torque M = Ja and a = angular

are, therefore, typically quite efficient.

acceleration, total power in the system

But designers who merely look at cata-

P T and power delivered to the load P L

log efficiency ratings of components

relate as:

can get fooled if they assume total efficiency is the sum of the individual

P T = P L (1 + 1 /λ);

ratings. Users also need to consider the effects of inertia on the system.

or efficiency is

For instance, a system with a servomotor, coupling, and gearhead tends to

η = P L /P T = λ/ (1 + λ ).

have a high moment of inertia and low mechanical stiffness. Such systems

The “drivetrain efficiency” graphic

require a low, robust inertia match—a

in fig. 2 shows that obtainable torque

ratio of the motor inertia to the load

with respect to obtainable power is

inertia of about 1:3—to perform well.

proportional to the mass moment of

Actuators that eliminate the coupling

inertia in the drivetrain. It describes

and mount the pinion directly into

the total inertia in the system that must

the motor shaft, in contrast, increase

be accelerated in terms of power and

torsional and tilting rigidity and limit

efficiency.

backlash. This reduces system inerinertia ratios of 10:1. For the system

Electronic Preloading

designer, that permits smaller motors

Most people would think that a 1:1 iner-

for the same application and, in turn,

tia ratio would be an ideal match. But

smaller cables and drives, less energy

looking at the graph, only 50 percent

consumption, and overall greater effi-

of the total power is delivered to the

ciency. Here’s a look at the underlying

load. It’s really an inefficient system.

math.

With robust controls, high stiffness,

tia, increases stiffness, and tolerates

Consider the simple “horizontal drive”

and low backlash, systems can toler-

system shown in fig. 1. For dynamic

ate higher inertia mismatch and use

Fig. 3: The four stages of motion.

gearsolutions.com

GearSolutions_January12.indb 54

12/20/11 2:32:32 PM

smaller motors for a given load, transferring more energy in

force preload. As the unit accelerates, the slave axis transi-

the system directly to the load. In addition to a more-efficient

tions to the opposite tooth flank and both actuators act in

system, a smaller, less-expensive motor requires less energy

tandem, but still without backlash. This is important because

to produce the same output.

traditional preloading systems do not let both axes work

Acceleration For an example of state of the art mechatronic systems, look

together. Instead, one axis always pushes against the other, creating inefficiencies.

no further than electronic preloading of rack and pinion linear

Comparing Efficiencies

actuators. These systems use a single rack with two pinions

During constant-speed movements, electronic preloading is

and two motors working in tandem, along with an electronic

disabled and both axes work together to carry the load. Inertia

controller. It gives backlash-free motion while minimizing

and workpiece resistance maintain backlash-free operation.

frictional losses, making these systems more precise and

During deceleration, the slave axis again transitions to the

energy efficient than ever. Consider the four different stages

opposite tooth flank, increasing restraint to help slow the

of motion depicted in fig. 3.

load and eliminate backlash. There is no backlash during load

Constant Speed

changes because the tooth and flanks never lose contact. As mentioned previously, linear motors have overall efficiency as

Electronic preloaded rack-and pinion drives have master and

high as 85 percent, though some are considerably lower. Ball

slave axes. At standstill they generate opposing torque and the

screws, depending whether or not preloaded, can have efficien-

restraint, or electronic preload, is at its maximum. The master

cies up to 90 percent, and rack and pinion systems can push

and slave engage tooth flanks facing in opposite directions to

efficiency to 97 percent.

eliminate backlash or “play” in the system.

Deceleration During acceleration, electronic preload is reduced. As the

about The authors: Miriam Metcalfe is with Wittenstein, Inc. Call (888) 534-1222 or visit www.wittenstein-us.com.

master axis causes motion, the slave axis eases the opposing

STOR-LOC MODULAR DRAWER SYSTEM

880 N. Washington Ave. Kankakee, IL 60901 Toll Free: 1.800.786.7562 • Fax: 1.800.315.8769 email: sales@storloc.com

Modular Drawer System

www.storloc.com JANUARY 2012

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PRODUCT ShoWCaSe

new products, equipment, and resources

Gleason Adds to Genesis Series

Gleason’s popular Genesis® series now includes 260H and 400H vertical gear hobbing machines for the production of spur and helical gears up to 260 mm in diameter, and 400 mm in diameter, respectively, and up to 700mm of axial travel to accommodate extra-long shafts. The new Genesis gear hobbing machines are particularly well-suited for the demands of today’s dry machining environment, featuring an exceptionally clean and uncluttered work chamber and a single-piece mineral cast polymer composite base/frame with superior damping and thermal stability. They are also among the most compact machines in their class, with a slimprofile design that makes it easier to both install the machines and integrate all styles of automation for cell/system application, as well as making it faster and more efficient for operators to manually load/unload parts and tooling. Go online to www.gleason.com. 56

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Burr-Rx Brushes from Weiler Weiler Corporation, the leader in nylon abrasive filament brushes, provides a complete offering of BurrRx™ deburring tools including power tube brushes, small-diameter wheels, Bore-Rx internal deburring tools, and large-diameter wheel, disc, miniature disc, and banded end brushes, all manufactured with an advanced ceramic-grain abrasive filament. Weiler offers the most comprehensive line of high aggression, compliant brushing tools that address practically any automated deburring need. The black nylon filaments of Weiler’s Burr-Rx brushes are co-extruded with an engineered ceramic abrasive grain, providing cut rates up to 400 percent faster than standard silicon carbide or aluminum oxide filaments. The extreme aggression of Burr-Rx brushes reduces cycle times by allowing the use of high feed rates and short dwell times, resulting in increased throughput and lower deburring costs. In addition, the brushes can remove burrs that are impossible to remove with conventional nylon abrasive filament brushes. Learn more at www.weilercorp.com.

CRYSTA-Apex S CMM from Mitutoyo The new CRYSTA-Apex®S Coordinate Measuring Machine from Mitutoyo America Corporation brings new levels of performance and economy to the 1.7 μm class of CNC CMMs. With a maximum error of MPEE = (1.7+3L/1000) μm, it more than doubles the effective measuring range at a given measurement tolerance as compared to typical CMMs in its class. Additionally, the CRYSTA-Apex S drive features high-speed (max 519 mm/s) and high acceleration (max 2,309 mm/s2). These advances result in higher throughput for greater productivity and lower total owning and operating costs. It uses the new UC-400® controller to manage digital servo system control loops for position, speed, and current. This makes it easy to implement various types of control algorithms. Additionally, the digital servo system has a wide dynamic range and is highly resistant to drift over time. Extreme rigidity helps the CRYSTA-Apex S maintain accuracy. The Y-axis guide rail is integrated into one side of the granite surface plate. Precision air bearings located on the bottom, front, rear and upper surfaces of the X-axis slider minimize vibration and ensure stability even during high-speed, high-acceleration operation. Learn more at www.mitutoyo.com.

JANUARY 2012

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Grease Test Kit from SKF The SKF Grease Test Kit introduces a portable and user-friendly technology for performing bearing grease condition assessments directly in the field. The kit enables users to easily take samples and evaluate grease consistency, oil bleeding characteristics, and contamination without special training or the use of harmful chemicals. The kit is equipped with instructions, methodology, relevant tools for sampling and testing, and guidelines to interpret test results. Only a very small sample size (0.5 grams of grease) is required to perform all three tests and the process can be conducted as frequently as necessary. Among benefits from the on-site testing and analysis, grease relubrication intervals can be adjusted according to real conditions; grease quality can be evaluated to detect possible unacceptable deviations from batch to batch; grease performance can be assessed to confirm verification of the grease’s suitability for a particular application; and underperforming greases can be identified to help pre-empt potential damage. The resulting knowledge ultimately can promote machine reliability objectives. Go online to www.skfusa.com.

New Turbo 10 Cutting Tool from Seco Seco has released another advancement for the square shoulder milling process with its new Turbo 10 cutting tool that is suitable for most roughing, semi-finishing and finishing operations. The cutter offers improved tool life and precision by optimizing cutting properties that reduce heat generation and cutting forces. As a highly versatile design, the Turbo 10 easily tackles slotting, contouring, helical interpolation and ramping applications with cutting diameters that range from 0.625” to 4”and a maximum cutting depth of 0.354”. The Turbo 10 employs a coated, pre-hardened cutter body with two different pitch configurations for meeting tight tolerances and providing high reliability. Mounting types for the Turbo 10 include Cylindrical, Weldon, Arbor and Combimaster. With strong, highly positive geometries, optimized edges, a wide range of industry-leading carbide grades and two different corner radii, the inserts used in conjunction with the Turbo 10 offer maximum levels of adaptability, accuracy and reliability. Visit online at www. secotools.com/us. 58

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SPECTRUM CMM from Carl Zeiss Carl Zeiss introduces the new SPECTRUM coordinate measuring machine. This bridge-type CMM meets the market’s demand for an economical, entry-level CMM with Carl Zeiss machine, sensor and software technology. Designed for general measurement, the SPECTRUM can be configured to meet your specific needs. With the Carl Zeiss RDS-C5 articulating probe holder and our XDT multi-point sensor or Renishaw TP20 touch-trigger, this CMM can measure angled features in difficult to reach locations. The articulating probe holder offers +/- 180 degrees of bi-directional rotation and permits indexing steps of 5 degrees reaching 5,184 angular positions for either sensor. SPECTRUM can also be configured with the XDT directly for general prismatic applications. SPECTRUM models offer x, y, z measuring ranges from 700 x 700 x 600 mm to 700 x 1000 x 600 mm. Hard-coat aluminum guideway elements offer a variety of benefits including corrosion resistance, hardness and wear resistance, electrical resistance, temperature resistance and a low friction coefficient. Learn more at www.zeiss.com/metrology.

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featuredSuppliers Midwest Gear Corporation — REF #101 Phone: 330-425-4419 • Fax: 330-425-8600 Email: sales@mwgear.com Website: www.mwgear.com New England Gear — REF #102 Phone: 860-223-7778 • Fax #:860-223-7776 Email: jeff@newenglandgear.com Website: www.newenglandgear.com R. P. Machine Enterprises, Inc. — REF #103 Phone: 704-872-8888 • Fax #:704-872-5777 Email: sales@rpmachine.com Website: www.rpmachine.com Repair Parts, Inc. — REF #104 Phone: 815-968-4499 • Fax #:815-968-4694 Email: rpi@repair-parts-inc.com Website: www.repair-parts-inc.com Havlik International Machinery, Inc. — REF #105 Phone: 519-624-2100 • Fax: 519-624-6994 Email: havlik@bellnet.ca Website: www.havlikinternational.com GQ Machinery Inc.— REF #106 Phone: 516-867-4040 • Fax: 516.223.1195 Email: george@gqmachinery.com Website: www.gqmachinery.com

GEAR ACCESSORIES, PARTS & TOOLING FELLOWS Model #10-4/10-2, All Parts Available REF#102 Tilt Tables for 10-2/10-4, Qty 2 REF#102 FELLOWS Parts Available For All Models REF#103 BARBER-COLMAN – PARTS AVAILABLE FOR ALL MODELS REF#103 G&E – PARTS AVAILABLE FOR ALL MODELS REF#103 GEAR HOBBERS/CUTTERS CNC LIEBHERR #LC-255 CNC, 6-Axis, 10” Dia, 10” Face, 4 DP, ‘87 REF#103 PFAUTER #PE-150, 6-Axis CNC, 6” Dia, 5 DP, 6” Face, Fanuc 18MI REF#103 SYKES #H160, 4-Axis CNC Hobber, 6” Dia, All the Features, ‘93 REF#103 G&E #60 S-2 CNC Gasher/Hobber REF#103 G&E #60SB-2C CNC, Gasher/Hobber REF#103 BARBER-COLMAN #16-36, 16” Dia, 4-Axis, 6 DP, 36” Face REF#103 LIEBHERR #LC-502 6-Axis CNC Gear Hobber, 20" Diam. Cap., Loading REF#103 LIEBHERR #L-652, 5-Axis 26” Dia,27” Face, 2 DP ‘09 REF#103 MUIR CNC Gear Hobber, 4-Axis, 118” Dia REF#103 LIEBHERR #L-252 3-Axis, 9.8” Dia, recontrolled 2008 REF#103 LIEBHERR #ET-1202 CNC - 70” Dia Internal, Single REF#103 LIEBHERR #ET-1802 CNC – 98” Dia Internal, 3-Axis REF#103 MITSUBISHI GD-20 CNC, 5-Axis, 8” Dia REF#103 G&E 120/188, CNC Gasher/Hobber, 188” Dia (5 Meter) REF#103 G&E #120GH, CNC, Gasher/Hobber, Twin Stanchion, 1/2 DP, 42” Face, ‘94 REF#103 PFAUTER P400H, 5-Axis, 18” Dia, 1 DP, Recontrolled ‘03 REF#103 G&E #160GH, CNC, Gasher/Hobber, New ‘07 REF#103 G&E #96GH, CNC, Gasher/Hobber, New ‘09 REF#103 HAMAI 60SP, CNC 4-Axis, 3.5" OD, 9" Face, 12 DP, New ‘89 REF#103 PFAUTER PE 300 AW CNC 6-Axis REF#103 GEAR HOBBERS/CUTTERS PFAUTER P1251 Hobbers s/n 25-276 and 25-277 REF#102 PFAUTER (1) RS-00 s/n 17593 REF#102 BARBER COLEMAN (1) 16-36 multi cycle s/n 4404 REF#102 BARBER-COLMAN #16-16, Multi-Cycle, Dual Thread Worm and/or Single Thread Worm REF#103 G&E #48H 48” Dia, 18” Face 2 DP, Universal REF#103 G&E #48H, 48” Dia, 35” Face, 3 DP, Gooseneck Attachment REF#103 LEES BRADNER HH-144 16” Dia, 144” REF#103 BARBER-COLMAN #6-16, 6 Multi-Cycle REF#103 G&E #36H Differential, Excellent Condition REF#103 BARBER-COLMAN #14-30, 14” Dia, 30” Face, 3.5DP REF#103 PFAUTER P-251 10” Dia, 9.6” Face, 4 DP REF#103 BARBER-COLMAN #14-15, 14” Dia, 15” Face, 1 to 4 Start Worm, Several REF#103 BARBER-COLMAN #16-16, 16” Dia, 16” Face, 6DP REF#103 BARBER-COLMAN #16-36, 24” Dia, C-Frame Style, 4 1/8” Bore REF#103 BARBER-COLMAN #16-56, 16” Dia, 56” Face, Differential REF#103

MACHINERY Contact Gear Solutions at 800-366-2185 to list your machinery.

BARBER-COLMAN #22-15, 22” Dia, 14” Face, Differential REF#103 DAVID BROWN, 138” Dia, Face 60”REF#103 G&E #24H Universal Head, Infeed, Tailstock, Differential, ‘50’s REF#103 HAMAI #120, 4.8” Dia, 4” Face, 12 DP, ‘70 REF#103 LIEBHERR #L-402, 16” Cap, 2-Cut Cycle, Crowning, ‘77 REF#103 LIEBHERR #L-650, 26" Dia Cap, 14.5" Face, 2.5 DP, New ‘70’s REF#103 MODUL #ZFZW 800, 29.8” Dia, 16.25” Face, 2.5 DP Crowing, 2-Cut REF#103 BARBER-COLMAN #1600-36, 16" Dia., 39.5" Face, 6 DP REF#103 CHONG QIN #Y3180H, 31.5 Dia., 15" Face, 3 DP REF#103 FELLOWS FH-200 Max Diam 7.87" Max Dia Pitch 5.08" REF#103 G&E #16H Gear Hobber, 16"Dia REF#103 BARBER-COLMAN #3 (6-10), Single & Triple Tread Worm HS REF#103 BARBER-COLMAN #6-10, 6” Dia, 10” Face, 16 DP REF#103 KOEPFER #140 , 2.75” DIa, 4” Face REF#103 KOEPFER #153B, 5.6” Dia, 5.9” Face REF#103 LANSING #GH-50, 50” Dia, 17.75” Face, 2 DP REF#103 LIEBHERR #L-252, 9.8” Dia, 7.9” Face, 4.2 DP REF#103 MIKRON #79 1.5 Dia, 26 DP REF#103 BARBER-COLMAN TYPE T REF#103 IUG –Craiova FD-3600 REF#103 LIEBHERR #L-401, 15.7” Dia 11” Face, 3DP REF#103 G&E #36HS 36”Dia, 14” Face 3 DP REF#103 PFAUTER #P-3000, 120” Dia, Single Index REF#103 SCHIESS RFW-10-S 55” Dia REF#103 SHIBURA HHC-250A Single Index REF#103 OVERTON #HD-400, 15.7” Dia, 12” Face, 3 DP, New ‘88 REF#103 SCHIESS 1 RF-10, Dia 60” 150” L, .50 DP REF#103 G&E #40TWG, 48” Dia, 18” Face, 3 DP REF#103 G&E #60S, 72” Dia, 14” Face, 1.25 DP REF#103 G&E #72H, 72” Dia, 24” Face, 1 DP REF#103 G&E #96H, 104” Dia, .50 Face, 1.25 DP REF#103 PFAUTER #P-630, 25” Dia REF#103 PFAUTER #2500, 100” Dia REF#103 TOS FO-16, Max Cut w/support 90” REF#103 PFAUTER P250 10” Dia REF#103 GE Hobber 200” Dia, 55” Face REF#103 GE/Fitchburg Hobber 32” Dia, 72” Face 1.25DP REF#103 JF Reinecker 40” Dia 35” Face REF#103 LIEBHERR L-160-R 6.5” Dia REF#103 MIKRON #102.04 , 4’ Dia, 5” Face REF#103 NIHON-Kikai NDH-1200 50” Dia REF#103 PFAUTER P-900 36” Dia REF#103 SCHIESS RF 40/60S 240” Dia 100” Face REF#103 BARBER-COLMAN #25-15 25” Dia, 15” Face, 2.5 DP REF#103 CRAVEN Horizontal , 18” Dia and 100” Length REF#103 KOEPFER #173B, .6.1” Dia, 7” Face REF#103 PFAUTER #P-630R, 25" Max. Spur Dia, 12" Max Rotor Dia. 12" REF#103 BARBER-COLMAN 2 1/2 -4, S/N 119, ’62 Hi-Production Spur Gear REF#104 BARBER-COLMAN 6-10 SYKES, Triple Thrd w/Lever Operated Collet Assy REF#104 BARBER-COLMAN 6-10 B&C Ltd, S/N 8079, Triple Thrd REF#104 BARBER-COLMAN 6-10, S/N 4626, ’57 Triple Thrd 3” Hob Slide REF#104 BARBER-COLMAN 6-10, S/N 4659R, ’56 Triple Thrd Adj Ctr Assy REF#104 BARBER-COLMAN 6-10, S/N 4665, ’57 Fine Pitch Prec Triple Thrd REF#104 BARBER-COLMAN 6-10, S/N 4701, ’58 Triple Thrd w/Power Down Feed REF#104 BARBER-COLMAN 6-10 M/C, S/N 4755, ’59 Triple Thrd w/MC Conversion REF#104 BARBER-COLMAN 6-10 Multicycle, S/N 4778R87, ’60 (’87 Rebuild), Sgl Thrd Hi-Spd REF#104 BARBER-COLMAN 6-10 M/C, S/N 4913, ’63 Triple Thrd w/90 Deg Hob Slide REF#104 BARBER-COLMAN 6-10 Multicycle, S/N 5055, ’66 Triple Thrd, 800 RPM REF#104 BARBER-COLMAN 6-10, S/N 5141, ’67 Triple Thrd w/Prec Hob Shift REF#104 BARBER-COLMAN 6-10 Multicycle, S/N 5148, ’68 Triple Thrd, 800 RPM REF#104 BARBER-COLMAN 6-10 Multicycle, S/N 5259, ’75 Triple Thrd w/Auto Hob Shift REF#104 BARBER-COLMAN 6-10, S/N 5353, ’77 Triple Thrd w/3” Hob Slide, 800 RPM REF#104 BARBER-COLMAN 6-10, S/N 5394, ’81 Fine Pitch Triple Thrd w/Dwell & Hob Rev REF#104 BARBER-COLMAN 6-16 M/C, S/N 5238, ’70 Triple Thrd, Recon ‘02 REF#104 BARBER-COLMAN 6-10, S/N 5407, ’82 Auto w/PLC Control REF#104 BARBER-COLMAN DHM, S/N 105, ’42 Double Thrd REF#104 BARBER-COLMAN 14-15, S/N 635R, ’53 Dbl Thrd, Fact Reb REF#104 BARBER-COLMAN 14-15, S/N 745, ’55 Dbl Thrd w/Dwell REF#104 BARBER-COLMAN 14-15 Dual Fd, S/N 938, ’62 Dbl Thrd, Comp Reco REF#104 BARBER-COLMAN 14-15, S/N 1055, ’65 Dbl Thrd w/New Hyd Sys REF#104

BARBER-COLMAN 14-15, S/N 1131, ’66 Dbl Thrd w/Hyd Tailctr REF#104 BARBER-COLMAN 14-15 Dual Fd, S/N 1261, ’67 Dbl Thrd w/Hyd Live Ctr REF#104 BARBER-COLMAN 14-15 Dbl Cut, S/N 1278, ’68 Dbl Thrd w/4-1/8” Bore REF#104 BARBER-COLMAN 14-30 Dual Fd, S/N 1371, ’71 4-Thrd w/Sizing Cycle REF#104 BARBER-COLMAN 22-15, S/N 923, ’62 Dbl Thrd, Dbl Cut REF#104 BARBER-COLMAN 16-11, S/N 184, ’50 Dbl Thrd w/Vert DRO REF#104 BARBER-COLMAN AHM, S/N 1896, ’42 Sgl Thrd w/3 Jaw Chuck REF#104 BARBER-COLMAN 16-16, S/N 2745, ’51 Sgl Thrd w/90 Deg Hd REF#104 BARBER-COLMAN 16-16, S/N 3171, ’53 Dbl Thrd, Spanish Nameplates REF#104 BARBER-COLMAN 16-16, S/N 3580, ’59 Dbl Thrd w/Diff & Auto Hobshift REF#104 BARBER-COLMAN 16-16 Multicycle, S/N 3641, ’60 Dbl Thrd w/Diff REF#104 BARBER-COLMAN 16-16, S/N 3660, ’57 Sgl Thrd REF#104 BARBER-COLMAN 16-16, S/N 4136, Dbl Thrd, “C” Style End Brace w/Diff REF#104 BARBER-COLMAN 16-16 Multicycle, S/N 4170, Dbl Thrd w/Jump Cut Cycle “ C” Style REF#104 BARBER-COLMAN 16-16, S/N 4473, ’73 4-Thrd w/Workclamp Cyl “C” Style REF#104 BARBER-COLMAN 16-16 Multicycle, S/N 4520, ’75 Dbl Thrd w/Gooseneck Slide REF#104 BARBER-COLMAN 16-16 Multicycle, S/N 4631, ’79 “C” Style End Brace, 4W Adj Ctr REF#104 BARBER-COLMAN AHM (36”), S/N 1152, ’42 Dbl Thrd REF#104 BARBER-COLMAN 16-36, S/N 4090, ’66 Dbl Thrd, “C” Style End Brace REF#104 BARBER-COLMAN 16-36 Multicycle, S/N 4232, ’68 Dbl Thrd “C” Style End Brace w/Diff REF#104 BARBER-COLMAN 16-56, S/N 3136R84, ’53 (Reb ’84), Dbl Thrd REF#104 BARBER-COLMAN 10-20, S/N 6700045890, ’76 Dbl Thrd w/2 Cut Cycle REF#104 TOS OFA Series Conventional Gear Hobbers, 12” & 40” Dia REF#105 TOS OHA Series Conventional Gear Shapers, 12” & 40” Dia REF#105 TOS FO-16 with single index 72” cap. REF#106 GEAR PINION HOBBERS & SPLINE MILLERS HURTH #KF-32A 15” Dia, 59” Face, ‘67 REF#103 GE/Fitchuburg Pinion Hob 32” Dia, 72” Face REF#103 MICHIGAN Tool #3237 REF#103 SCHIESS 1 RF-10, 60” Dia REF#103 WANDERER GF 345 CNC Hobbing /Milling Machine 4-Axis 24" Swing x 240” Length REF#103 FITCHBURG Pinion Hobber 42” Dia, 72” Dia REF#103 CRAVEN Horizontal, 18” Dia and 100” Length REF#103 Craven horizontal 36” dia 96” length 73/4” hole REF#106 GEAR HOB & CUTTER SHARPENERS (incl CNC) ARTER #A-12, 12” Rotary Surface Grinder for Sharpening Sharper Cutters REF#103 BARBER-COLMAN #6-5, 6" Dia, 5" Length, Manual Dresser, ‘57 REF#103 BARBER-COLMAN 10-12, 10" Dia, 12" Length, Spark Out REF#103 FELLOWS #6SB, Helical Cutter Sharpener, 6” Dia, up to 50 Degrees REF#103 KAPP #AS-305GT, 1 DP, 28" Grind Length, 10" Diam., Str. & Spiral REF#103 KAPP #AS204GT, 10” Dia, Wet Grinding, CBN Wheels, ‘82 REF#103 BARBER-COLMAN #3 HS, Hob Sharpener, 4" Max. OD., 4" REF#103 BARBER-COLMAN #4-4HRS, Hob Sharpener, 4" Max. OD. 4" REF#103 REDRING MODEL #SGH "PREIFORM" SHAVE CUTTER GRINDER/SHARPENER REF#103 STAR 6X8 HOB SHARPENER PRECISION GEAR & SPLINE HOBBER REF#103 BARBER-COLMAN 2-2 1/2 , 2.5” Dia REF#103 KAPP #AST-305B, 27.5” Dia, REF#103 KAPP AS-410B REF#103 GLEASON #12 Sharpener, 3-18” Cone REF#103 BARBER-COLMAN 2 1/2-2, S/N 16, ’66 Wet w/Auto Feed REF#104 BARBER-COLMAN 6-5, S/N 110R, ’55 Wet w/Auto Dress & Sparkout REF#104 BARBER-COLMAN 6-5, S/N 396, ’66 Wet w/Auto Dress & Sparkout REF#104 BARBER-COLMAN 6-5, S/N 433, ’69 Wet w/Auto Dress & Sparkout REF#104 BARBER-COLMAN 10-12, S/N 643R83, Wet w/Auto Dress, PC Control, Fact Reb ‘83 REF#104 TOS OHA Series CNC Gear Shapers, 12” & 40” Diameter REF#105 TOS OFA Series CNC Gear Hobbers, 12” & 40” Diameter REF#105

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GEAR SHAPERS CNC 36” Shapers, 14” Throat Risers, 53” of Swing, Qty 3 REF#102 FELLOWS #10-4/10-2, Qty 150 REF#102 HYDROSTROKE #50-8, Qty 2 REF#102 HYDROSTROKE #20-8, Qty 5 REF#102 HYDROSTROKE #FS630-125, Qty 1 REF#102 HYDROSTROKE #FS400-90, Qty 2 REF#102 FELLOWS #20-4, Qty 6 REF#102 FELLOWS #48-8Z, Qty 1 REF#102 FELLOWS #FS-180, 3-5 Axis, 7” Dia, 1.25” Face., 6 DP, New ‘88 REF#103 LIEBHERR #WS-1, 4-Axis CNC, 8" OD, 2" Stroke, Fanuc 18MI REF#103 LORENZ # LS-180, 4-Axis CNC, 11” OD, 2” Stroke, 5 DP REF#103 LORENZ #LS-304 CNC Gear Shaper 5-Axis Heckler & Koch Control REF#103 LORENZ #LS-156 CNC Gear Shaper Dia 6” REF#103 FELLOWS FS400-125, 16” Dia, 3.5 DP 5” Face REF#103 SCHIESS RS-20 S, 12” Stroke, 118” Dia REF#103 FELLOWS #10-4 3-Axis (A/B), 10" Dia, 4" Face, 4 DP New .’09 REF#103 RP-GS 800 CNC, 4-Axis, Max Dia 31.5”, Face 9”, 2.5 DP REF#103 RP-GS 400 CNC, 6-Axis, Max Dia 15” Face 4”, 3 DP REF#103 STANKO /RPM #48-8 Gear Shaper CNC, Fanuc 18 REF#103 FELLOWS #10-4 2-Axis, 10” Dia 4” Face REF#103 FELLOWS #20-4 3-Axis 10” Dia, 4” Face REF#103 FELLOWS FS400-90 Hydro-stroke Gear Shaper CNC Nominal Pitch 15.7" REF#103 RP-GS 1500 CNC, 4-Axis, Max Dia 49.2”, Face 12”, 2 DP REF#103

GEAR HOBBERS G&E 96H, roughing & finishing 104” dia. REF#106 TOS FO-16 single index 80” dia. Yr 1980 REF#106 Craven spline & pinion hobber 36” x 96” REF#106 G & E 48H 48” dia. Diff, OB, change gears REF#106 Pfauter hobber P-1800 70” dia. 29” face yr 1980 REF#106

GEAR SHAPERS FELLOWS #10-2, (10” Dia), 2” Face REF#102 FELLOWS #10-4, (10” Dia), 4” Face REF#102 FELLOWS (200) 10-4 / 10-2 Shapers REF#102 FELLOWS (1) 50-8 Hydrostroke Shaper s/n 36607 w/ 6 axis 16iMB Fanuc (2009) REF#102 FELLOWS (1) 20-8 Hydrostroke Shaper s/n 35932 w/ 6 axis 16iMB Fanuc (2009 REF#102 FELLOWS (1) #7 125A Face Gear Machine REF#102 FELLOWS (2) #3 Face Gear Machine REF#102 (1) 4ags with adjustable Helical Guide s/n 30634 REF#102 (1) #7 125A adjustable Helical Guide REF#102 FELLOWS (1) FS630-200 Hydrostroke Shaper s/n 36943 w/ 6 axis 16iMB Fanuc (2009) REF#102 FELLOWS (3) Tilt Table 10-4 / 10-2 w/ 4 axis 21i Fanuc Controller (2009) REF#102 FELLOWS (2) Swing-away center support for 10-2 / 10-4 REF#102 FELLOWS (1) FS630-170 Hydrostroke Shaper s/n 36732 w/ 6 axis 16iMB Fanuc (2009) REF#102 FELLOWS (2) FS400-170 Hydrostroke Shaper w/ 6 axis 16iMB Fanuc (2009) REF#102 FELLOWS (4) FS400-125 Hydrostroke Shaper w/ 6 axis 16iMB Fanuc (2009) REF#102 FELLOWS (1) 20-4 Shaper s/n 35687 w/ 4 axis 21i Fanuc Controller (2009) REF#102 FELLOWS (1) 48-8Z Shaper w/ 14” throated riser (53” of swing) REF#102 FELLOWS (1) Horizontal Z Shaper s/n 21261 REF#102 FELLOWS (1) 4-B Steering Sector Gear Shaper w/ 18iMB 4 axis Fanuc controller s/n 34326 REF#102 FELLOWS (1) 36-10 Gear Shaper REF#102 FELLOWS (1) 10x6 Horizontal Z Shaper REF#102 FELLOWS (1) 36-6 Gear Shaper w/ 13” riser s/n 27364 REF#102 FELLOWS (1) 10-4 Shaper w/ 3” riser w/ 4 axis 21i Fanuc Controller (2009) REF#102 All Parts for 10-4/10-2 Fellows Gear Shapers REF#102 FELLOWS #36-8, 36” Dia, 8” Face REF#103 FELLOWS #100-8 100” Dia, 8” Face REF#103 FELLOWS #612A, 615A, #645A REF#103 FELLOWS #10-4, 10” Dia, 4” Face, 4 DP REF#103 FELLOWS #4A Versa, 10” Dia, 3” Face, 4 DP, New ‘70’s REF#103 FELLOWS #10-2, 10” Dia, 4” Face, 4 DP REF#103 FELLOWS #20-4, 20” Dia, 4” Face, 4 DP, ‘70’s REF#103 MAAG #SH-100/140, 57” Dia., 12.6” Face, 2 DP, Internal Attachment REF#103 FELLOWS #3-1,/3GS, 3” Max Dia, 1” Face, Pinion Supp, High Precision REF#103 FELLOWS #48-6 INTERNAL GEAR SHAPER ONLY,0-72"OD,6" Face REF#103 LORENZ #SJV00, 7” Dia, 2” Face, ‘50’s REF#103 MAAG #SH-100K 47”/12.6”/1.7 ‘60’s Internal Attachment REF#103 MAAG #SH-150, 57" Dia.12.6" Face REF#103 PFAUTER #SH-180 Shobber 7" capacity hobbing, 9.45" cap REF#103 FELLOWS #36-6 Max Dia 36” 6” Face, 3 DP REF#103

FELLOWS #HORZ Z SHAPER, 10 x 6 Dia 27.6 Face 8.5” REF#103 MAAG #SH-75C, 30”/8”/2.5”/’52 REF#103 MAAG #SH-600, 235” Dia 36”, 1DP REF#103 FELLOWS #4GS & 4AGS, 6” Dia, 2” Face, 4DP, ’68, Ref.# Several REF#103 TOS OH-6, Dia 19.7” REF#103 FELLOWS #624A, 18” Max Dia, 5” Face REF#103 FELLOWS #7, #7A, #715,# 75A, #715, #725A, 7” Dia, 0-12” Risers, Several Avail REF#103 MAAG #SH-180-300 , Max Dia 118”/ 16.9” Face REF#103 MAAG #SH-350/500, Max Dia 197” REF#103 MICHIGAN #18106 SHEAR-SPEED GEAR SHAPER,14" Dia, 6"Face REF#103 FELLOWS Model Z Shaper, 5" Stroke, ‘50’s REF#103 STAEHELY SHS-605, Gear Shaper REF#103 FELLOWS #6, #6A, #61S, From 18”-35” Dia, 0-12” Risers REF#103 FELLOWS #8AGS Vertical Gear Shaper, 8” Dia, 2” Face, 6-7 DP REF#103 TOS OHA50 CNC 5 20” Dia 5” Face REF#105 Fellows 36-6 Shaper (2) 12.5" Risers 6" Stroke Mint YR 1969 id 3616 REF#106 Fellows 36-6, shaper W/6” riser, change gears REF#106 Magg shaper SH4580-500S, 206”dia. 26” face REF#106 Magg shaper SH250, 98” dia. 26” face REF#106 Fellows #10-4,7” riser yr 1980 REF#106 GEAR DEBURRING/CHAMFERING/POINTING CROSS #50 Gear Tooth Chamferer, 18” Dia, Single Spindle REF#103 CROSS #75 Gear Tooth Chamferer, 10” Dia, 10” Face, ‘52 REF#103 REDIN #18, 28” Dia, 2, 3, 4 Spindle, Deburrer/Chamfer, PLC’s, Tilt Table REF#103 REDIN #20D, 20” Dia, Twin Spindle, Deburrer/Chamfer REF#103 SAMPUTENSILI #SCT-3, Chamf/Deburrer, 14” Dia, 5” Face, ‘82 REF#103 SAMPUTENSILI #SM2TA Gear Chamfering Mach, 10” Max Dia, (3) New ‘96 REF#103 REDIN #24 CNC Dia 4” Setup Gear Deburring REF#103 CROSS #60 Gear Tooth Chamferer, 10” Dia, Single Spindle REF#103 FELLOWS #100-180/60 CNC Max Dia 180”, Single Spindle REF#103 CIMTEC #50 Finisher REF#103 RPM #GC-500 CNC 20” Dia, Single Spindle REF#103 CROSS #54 Gear Deburrer, 30” Dia, 18” Face REF#103 RED RING #24 Twin Spindle Dia 4” REF#103 CROSS #55 Gear Deburrer, 18” Dia, 1.5 Spindle REF#103 GLEASON GTR-250 VG CNC 5-Axis REF#103 GRATOMAT #300L REF#103 GEAR Honers Fassler #K-400 CNC Hone 16" Dia REF#103 Fassler K-400A CNC Hone 16” Dia REF#103 Kapp #CX120 Coroning 4.7” Dia REF#103 Red Ring GHD-12, 12” Dia, 5.5 Stroke REF#103 Red Ring GHG, 12” Dia, 5.5 Stroke REF#103 Kapp #VAC65 Coroning 10” Dia REF#103 GEAR SHAVERS Red Ring #GCX-24" Shaver, 24” Dia, 33” Stroke REF#103 Red Ring #GCU-12, 12” Dia, 5” Stroke REF#103 Red Ring #GCU-8 Shaver. 8” Dia REF#103 Red Ring #GCY-12, 12” Dia, 5” Stroke REF#103 Red Ring GCI 24, 12.75” Dia, 5” Stroke REF#103 Nachi Raso CNC Shaver, 3-Axis REF#103 Michigan #873-24A, 24” Dia, 15” Face, 2 DP REF#103 GEAR GENERATORS, STRAIGHT BEVEL GLEASON #37 Str. Bevel Planer, 6” Dia REF#103 GLEASON #54 Str, Bevel Planer, 60” Dia REF#103 GLEASON #496 Straight.& Spiral. 7.5” Dia REF#103 GLEASON 14, Coniflex Straight Bevel REF#103 GLEASON 24A Straight Bevel REF#103 GLEASON 725-Revacycle, 6” Dia REF#103 GLEASON 726-Revacycle, 5” Dia REF#103 GLEASON 2A, 16” Cone REF#103 GLEASON #116, 9” Cone, 2.75 Face REF#103 GLEASON #104 w/Helical Motion, Coniflex, Straight Bevel REF#103 GEAR GENERATORS, SPIRAL BEVEL (HYPOID) GLEASON #645 Hypoid Generators REF#103 GEAR GRINDERS CNC HOGLUND, Model #264, CNC Internal Gear Grinder REF#103 KAPP #VAS-482 CNC GEAR GRINDER, 11.8" SWING DIA REF#103 GLEASON Phoenix 200G Hypoid Grinder CNC REF#103 REISHAUER RZ-801 CNC, 31.4” Dia REF#103 NILES ZSTZ 06-800 CNC, 31.5” Dia, 11” Face REF#103 NILES ZSTZ 08-800 CNC, 32” Dia, 11” Face REF#103 RED RING #SF-500 CNC Int/Ext, 26” Dia, REF#103 GLEASON/TAG – 400 CNC, 16” Dia REF#103 HOLFER PROMAT 200 , 7.87” Dia CNC Gear Grinder REF#103

GEAR GRINDERS #27, #137, and #463 Gleason Hypoid Spiral Bevel gear grinder generating Cams (2 full sets) REF#102 Springfield Vertical Grinder, 62" Table, #62AR/2CS, 3.5A Rail Type, 70" Swing REF#102 REISHAUER ZA, Gear Grinder, 13" Dia, 6" Face, Strait & Helix REF#103 RED RING #SGJ-18, 18” Dia., 9” Face, Internal Attachment, New ‘78 REF#103 DETROIT Gear Grinder #GGI-16x3A, Internal Gear Grinding, 16" OD REF#103 MAAG SD-32-X REF#103 GLEASON #463, 15” Dia REF#103 HOFLER BHS H1603-2000, 78.7” Dia REF#103 NILES ZSZT-3500, 139” Dia REF#103 KAPP VAS #331, Gear Grinder REF#103 NILES ZSTZ-1250/5000 49.2Dia REF#103 GEAR RACK MILLERS/SHAPERS MIKRON #134 Rack Shaper, 17.4" Length, 1.1" Width, 16.9 DP REF#103 SYKES VR-72 Vert Rack Shaper, 72" Cut Length, 4DP, 4" Stroke, ‘80 REF#103 SYKES VR-60 Vert Rack Shaper, 60” Cut Length, 4DP, Stroke 4” REF#103 GEAR THREAD & WORM, MILLERS/GRINDERS LEES BRADNER #HT 12x54, Dia 12” /54” REF#103 MOREY-SHIELDS THREAD MILLER, Dia 12” REF#103 BARBER-COLMAN #10-40, 10" Dia., 40" Length, 4 DP REF#103 EXCELLO #31L, External Thread Grinder, 5" OD, 20" Grind Length REF#103 EXCELLO #33 Thread Grinder 6” Dia 18” Length REF#103 EXCELLO #35 and #35L Thread Grinder, 84" Between Centers REF#103 EXCELLO #39 Int. Thread Grinder, 9.5" Max Dia., 10" Max. Swing REF#103 HURTH #KF-33A Multi-Purpose Auto-Milling Machine 88” REF#103 LEES BRADNER #HT12x102, Extra Large Capacity REF#103 J&L AUTOMATIC THREAD GRINDER, 6" X 36", ‘38 REF#103 LEES BRADNER #HT 12"x 144" Thread Mill, 12" Dia, REF#103 WALDRICH COBURG WHIRLING, 3” Dia, 118” Length REF#103 LEES BRADNER # LT 8” x 24” 8” Dia REF#103 HOLROYD 5A 24.8 “ Dia REF#103 HECKERT WMW #ZFWVG REF#103 LEES BRADBER WORM MILLER REF#103 GEAR TESTERS/CHECKERS (incl CNC) FELLOWS (1) RL-600 Roll Tester s/n 35814 REF#102 FELLOWS (1) 24H Lead Checker s/n 32289 REF#102 GLEASON (1) #14 Tester s/n 31907 REF#102 GLEASON (1) #6 Tester s/n 19316 REF#102 FELLOWS (1) 20 M Roller Checker REF#102 FELLOWS (1) 20 M w/ 30” Swing Roller Checker REF#102 FELLOWS (1) #8 Micaodex s/n 36279 REF#102 David Brown #24 Worm Tester REF#103 Fellows 12H Gear Tester REF#103 Fellows #12M Gear Tester REF#103 Fellows 20M Gear Tester REF#103 Felows #24 Involute Measuring Instrument REF#103 Gleason #4, #6, #13 and #17 Testers REF#103 Hofler EMZ-2602 Int/Ext Gear Tester 102” REF#103 Klingelnberg #PFSU-1200 Gear Tester REF#103 Klingelnberg #PFSU-1600 Gear Tester-2001 REF#103 Klingelnberg PWF-250 Tester REF#103 Kapp Hob Checker WM 410 REF#103 Maag #ES-430 Gear Tester REF#103 Maag #SP-130 Lead and Involute Tester REF#103 National Broach Gear Tester GSJ-12 REF#103 Oerlikon #ST2-004 Soft Tester REF#103 Maag #SP-60- Electronic Tester REF#103 Parkson #42N Worm Gear Tester REF#103 Fellows #24H Tester REF#103 Gleason #104 Tester REF#103 Vinco Dividing Head Optical Inspection REF#103 MISCELLANEOUS WARNER & SWAYSEY #4A M-3580 Turret Lathe, 28 1/4 Swing, 80” Centers, 12” Spindle Hole 50/25 Motors, 480/3 Phase, Year 1965 REF#101 Springfield Vertical Grinder, 62" Table, #62AR/2CS, 3.5A Rail Type, 70" Swing REF#102 GLEASON #529 Quench, 16" Diameter REF#103 VERTICAL TURNING LATHES AND MORE - Please Check Our Website To View Our Entire Inventory REF#103 TOS SU & SUS Series Conv Lathes REF#105 TOS SUA Series CNC Flat-Bed Lathes REF#105 Change gears for G & E hobber REF#106

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Magna-Rails and Magna-Rolls from Eriez Eriez® Magna-Rails® and Magna-Rolls® magnetically convey, transfer, control, elevate, reposition, hold or orient basic ferrous materials and finished parts. These products have been the industry standard for more than 40 years and are used primarily on automated conveyor lines. An ever-present need within many processing industries is the ability to hold steel parts firmly on moving belt conveyors. Such conveyors, fitted with Eriez Magna-Rails, ensure that parts do not fall off, even when being elevated or lowered. These magnetic elements, positioned under conveyor belts and secured by mounting brackets, provide a safe, positive hold for ferrous parts at high speeds in any direction, even up inclines as steep as 90 degrees. Two types of permanent magnet Magna-Rails are offered: Erium® 45 (Alnico) and Erium 25 (Ceramic). Straight sections are available in various holding strengths, and in increments up to 10 feet (3 m) in any one section. They can be positioned to provide any desired length. In addition to the Erium 45 and Erium 25 models, an Electro Magna-Rail is available for special applications where on/ off power is required. Electro Magna-Rails are built with a 3-3/4" (95 mm) face width in standard 12" (304 mm) as well as special lengths. Go online to www.eriez.com.

MarSurf M 400 Skidless Surface Gage from Mahr Federal Mahr Federal will be featuring the addition of an economical and powerful new skidless surface evaluation system to its MarSurf® line of mobile surface metrology systems at MD&M WEST, February 14-16, 2012, at the Anaheim Convention Center in Anaheim, California. Mahr Federal will occupy booth #3069. The new MarSurf M 400 features proprietary motorized probe height adjustment that quickly and automatically zeros the probe in seconds and can cut measurement time in half. The M 400 also features a magnetic, breakaway probe mounting system that protects sensitive probes from accidental damage and facilitates fast probe changes. The MarSurf M 400 measures all common international parameters, and features Bluetooth connectivity between the measuring system and the evaluation unit with integrated thermal printer. Skidless tracing of surface characteristics allows the capture of primary, waviness, and roughness profiles for the evaluation of more complex parameters. More information is available at www.mahr.com. JANUARY 2012

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< Continued From Page 16 “We are committed to helping customers develop the skills required in the area of metal cutting technology,” says Jacobsen. “In this new role I hope to encourage a higher level of knowledge by offering ways to improve machining processes and profitability. We are also committed to helping all of our employees continue their education by offering a comprehensive selection of metal cutting technology and business courses in both a classroom and e-learning environment.”

streamlines the selection process of Sumitomo’s most ecofriendly drive, the patented, highly efficient, maintenance free Hyponic. Users quickly receive results that include downloadable 2D and 3D CAD files, product literature, and a technical specification sheet dynamically generated from the actual configured unit. This unique interactive tool enables the users to request a quote, and provides specific product dimension and weight details based upon their configuration. Registered users who are current Sumitomo customers also have the ability to produce their own quotations. Located at www.smcyclo.com/configurator, Sumitomo’s product configurator is a simple and efficient way to customize power transmission products to meet the needs of specific applications. For more than 40 years, Sumitomo Machinery Corporation of America has grown as a global leader in the power transmission industry, offering a wide variety of products for OEM and industrial applications. Go online to www.smcyclo.com.

Mitutoyo America Corporation Announces New President

Jacobsen earned an MBA degree in management from Rensselaer Polytechnic Institute and has a bachelor’s degree in marketing. He is also a certified facilitator for Franklin Covey’s 7 Habits for Managers and Paradigm Learning’s Zodiak business acumen course. He is a board member with the Industrial Supply Association (ISA) and the United States Cutting Tool Institute (USCTI), and he has been a part of the Sandvik Coromant team for 15 years in a variety of management positions. Sandvik Coromant is a world-leading supplier of cutting tools and tooling systems for the metalworking industry and is represented in 130 countries. It has 25 state of the art Productivity Centers located around the world to provide customers and staff with continuous training in tooling solutions and methods to increase productivity. Sandvik Coromant is part of the tooling business area of the Sandvik Group. Learn more at www.sandvik. coromant.com/us.

Online Hyponic Product Configurator from Sumitomo Sumitomo Machinery Corporation of America (SMA), U.S. headquarters for Sumitomo Drive Technologies, continues to enhance their customer service with the launch of their online Hyponic Product Configurator application. The user-friendly application

Shigeyuki Sasaki has been appointed the new president at Mitutoyo America Corporation, headquartered in Aurora, Illinois. Sasaki has served numerous roles within Mitutoyo Corporation for the last 35 years including new product development and quality control departments in Utsunomiya, Japan; manager of purchasing and planning in Mitutoyo Germany; general manager in Mitutoyo South America; and recently vice president and executive vice president of Mitutoyo America Corporation. He will remain as an active member of Mitutoyo Corporation’s board of directors. “To retain the leadership role in the metrology market Mitutoyo America Corporation is committed to continue providing high tech, durable products which meet our customers’ demands. We are excited to move forward to the next level under the guidance of Mr. Sasaki, whose leadership success has been a result of taking a hands-on, bottom building, and cross-functional communication approach,” says John Westhaus, executive vice president of Mitutoyo America Corporation. Sasaki succeeds Mikio Yamashita, who served as president of Mitutoyo America Corporation since 2006. Yamashita will return to Mitutoyo Corporation headquarters in Kawasaki-shi, Kanagawa, Japan at the end of the year, but will always be fondly remembered at Mitutoyo America for his insightful wisdom, compassionate nature and enthusiastic personality. He will continue his career with the corporation where he previously served as president of Mitutoyo Canada, vice president of Mitutoyo Netherlands, logistics manager of Mitutoyo Germany, and sales manager of Mitutoyo Netherlands. John Westhaus, formerly vice president of capital equipment sales, will assume Sasaki’s role of executive vice president. He has held many positions within Mitutoyo America Corporation throughout his 28 years of service with the company. Mitutoyo Corporation is the world’s largest provider of mea-

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MARKET

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TOS gear hobber Model FO-16 with single index, 72” dia.23” Face OB support change gears YR 1980

Save $25 by scanning this code Fellows #10-4,7” riser yr 1980

JANUARY 2012

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surement and inspection solutions, offering the most complete selection of machines, sensors, systems, and services with a line encompassing CMM (Coordinate Measuring Machines), vision, form, and finish measuring machines, as well as precision tools and instruments and metrology data management software. Mitutoyo’s nationwide network of Metrology Centers and support operations provides application, calibration, service, repair, and educational programs to ensure that its 6,000+ metrology products will deliver measurement solutions for customers throughout their lifetime. Visit online at www.mitutoyo.com.

Shell Unveils New LubeMatch Web Site Shell Lubricants announces the launch of its new, improved Shell LubeMatch online lubricant and grease selector service. With user-friendly navigation and easier to digest page layouts, this online service recommends the right choice of Shell lubricants and greases for specific industrial, off-highway, and agricultural applications, and it has been designed especially for the busy industrial environment. In addition to identifying oils that meet the equipment manufacturer’s specifications, Shell LubeMatch (www.shell.com/lubematch) provides jargon-free guidance on the relative benefits of different Shell products. This enables maintenance professionals to identify Shell lubricants that provide additional performance benefits or address specific problems, for example extended oil drain intervals (ODIs) in order to minimise the downtime and maintenance costs associated with oil changes. Searching by equipment type, make, and model—an easy threestep process—Shell LubeMatch provides recommendations for leading Shell Lubricants brands such as Shell Tellus (hydraulic oils), Shell Omala (gear oils), Shell Corena (compressor oils), Shell Tonna (slideway oils), and the recently introduced Shell Gadus line of greases. The Web site is delivered through a global platform available across 120 countries and in 26 languages, making it the most comprehensive and integrated lubricant selection tool available from any of the major oil companies. Louise Horobin, global brand manager, says “Many of our customers recognize the importance of correct lubricant choice and application, but lack the time to keep up-to-date with the latest products. As the leading global lubricants supplier we have a wealth of experience in applying the optimum lubricant technology to deliver the best performance and protection. Shell LubeMatch enables our customers to benefit from this via a quick and easy to use Web site.” Other improved features of the new Shell LubeMatch include: •E asier navigation, with the ability to search by equipment type, make, and model rather than product brands; • Improved look and feel, including images of product packaging for easier identification in an industrial environment; • All-in-one lubricants recommendation for all equipment compartments including engines, hydraulics, gearboxes etc.; • Easy links to download technical and safety datasheets where more detail is required;

•A bility to email recommendations to the user’s own account for future reference; • Ability to convert the recommendations into a PDF format for easier sharing and reference; • UK SMS function being piloted in the UK and Germany, enabling users to send text recommendations from the site to their own mobile phone. The redesign of Shell LubeMatch follows the increasing popularity of the original tool. In 2010, the existing Shell LubeMatch site received over seven million hits, with usage predicted to hit at least 10 million by the end of 2011. The development of Shell LubeMatch also forms part of a newly designed Shell Lubricants Web site for the industrial, off-highway, and agricultural sectors. The site provides information on all Shell Lubricants products, as well as insights into the latest technology for delivering enhanced protection and efficiency benefits. The new site is available at www.shell.com/lubricants.

American Wera to Represent MAE Line of Presses Effective October 1, 2011, an agreement was reached by American Wera, Inc., and MAE Götzen GmbH of Erkrath, Germany, for representation of the MAE line of straightening presses, wheel set presses, and hydraulic presses in the North American market comprising Canada, Mexico, and the United States. For MAE, American Wera will supply equipment, application engineering, onsite commissioning, training, and all after-sale service operating from its headquarters in Ann Arbor, Michigan, and sales and service center in Queretaro, Mexico. The company’s existing network of sales representatives will handle this new line under the direction of Joseph Kemple, product manager for MAE. MAE offers a broad line of manual, semi-automatic, and automatic straightening equipment with press forces to 25,000 kN, used particularly in the automotive, heavy equipment, steel, rail, and OCTG markets on round, profiled, and complex shaped workpieces in lengths up to 100 feet. MAE machines possess the high accuracy and repeatability necessary for extremely tight straightening tolerances on such large workpieces. Depending upon the workpiece, the type of machine may be electromechanical or hydraulic. All hydraulic presses are equipped with the MAE patented BiPAC hydraulic control systems for large energy savings. Finally, MAE also offers special application presses in C-frame, as well as four-column styles with press forces to 10,000 kN. These special application presses are typically used in forming and calibration. Scott Knoy, vice president of sales for American Wera, says “We believe the MAE line will complement our existing equipment, making us a greater value adder to current customers, plus it will open new markets where our expertise can be helpful to a variety of end product manufacturers.” Executing the agreement were American Wera President Walter Friedrich and MAE Managing Director Ruediger Goetzen. For more information on this announcement, please call (734) 973-7800 or go to www.american-wera.com.

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advertiser INDEX

COMPANYâ&#x20AC;&#x2C6;NAME............... PAGE NO. AJAX Rolled Ring and Machine................................................... 13 Allen Adams Shaper Services..................................................... 65 Allied Sinterings Inc..................................................................... 14 American Wera Inc..................................................................... 21 Banyan Global Technologies....................................................... 45 Bourn & Koch............................................................................. 67 Cincinnati Gearing Systems........................................................ 31 Clarke Gear Co........................................................................... 16 Clifford-Jacobs Forging............................................................... 35 DT Technologies sa..................................................................... 16 Encoder Products Company....................................................... 47 Engineered Tools Corporation (ETC).......................................32-33 Gear Solutions............................................................................ 59 GQ Machinery Inc....................................................................... 65 Hanik Corporation....................................................................... 67 Innovative Rack & Gear Co......................................................... 65 Ipsen International...................................................................... 39 KAPP Technologies....................................................................IFC Klingelnberg GmbH...................................................................... 2 Luren Precision........................................................................... 46 Mitsubishi Heavy Industries America Inc..................................... BC National Bronze and Metals Inc................................................... 52 New England Gear........................................................................ 7 Niagara Gear Corp...................................................................... 14 Nitrex Metals Inc......................................................................... 45 Proto Manufacturing Ltd............................................................. 11 Process Equipment Co............................................................... 55 R P Machine Enterprises Inc....................................................... 60 Raycar Gear and Machine Co..................................................... 12 Repair Parts Inc.......................................................................... 47 Riverside Spline & Gear Inc...................................................... 9,49 Saikuni USA................................................................................ 65 Sandvick Coromant.................................................................. IBC Solar Atmospheres..................................................................... 25 Stor-Loc..................................................................................... 55 The Broach Masters..................................................................... 4 The Company Corporation.......................................................... 65 The Gear Works--Seattle Inc....................................................... 65 TMFM LLC................................................................................. 52 Toolink Engineering Inc................................................................. 1 Walker Forge Inc......................................................................... 37 Willman Industries....................................................................... 53

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Q&A Jeff Estes director

Partners in THINC/Okuma

GS: Tell us the story behind Partners in THINC. JE: Okuma introduced THINC—The Intelligent Numerical Control—in 2004, which is a PC-based operating platform using the Okuma Sampling Path (OSP) control as a foundation. THINC’s open architecture allows integration with nearly any application or peripheral, so it was meant to be highly adaptable and customer driven from the very beginning. We established Partners in THINC three years later, in 2007, as a means of bringing together experts from around the world representing manufacturers of the equipment that will be linked by THINC, with the goal of harnessing their knowledge to provide customer solutions. As an example, one of our first projects involved designing a cell for a wheel manufacturer, so we brought together the developers of robotics, tooling, workholding, material handling, and others to design the most-efficient production system we could. Then we shared the results of our work with the client, saying “we guarantee that this cell will provide you with X amount of uptime, but if you break up the package you void the guarantee.” We’ve assembled the partners in our program very carefully, after all, so we can only guarantee our production figures if component parts of the cell design remain intact, as this wheel manufacturer chose to do.

GS: How did potential customers react to this model? JE: We share our proposals with top leadership, and what they found attractive was the guaranteed uptime. But people want to have choices, too, so we decided to have no more than two or three companies representing each market sector as part of the group. But they are what we consider to be the top manufacturers in the world— companies like Fanuc Robotics, Blum, Schunk, Marposs, Kennametal, and Sandvik Coromant, just to name a few of our 41 members—so that inspires a great deal of confidence in itself. So if we’re asked to design a manufacturing cell for a company we can recommend a selection of proven solutions and systems. But we always make clear that if someone insists on a make or manufacturer that isn’t part of our group, we can no longer guarantee the end results. GS: Tell us more about how this process works. JE: While we have worked on greenfield projects, where a company is building a new facility and wants us to help design their production line from square one, most often we’re approached by companies with specific challenges to overcome. A client might visit us here at our 58,000 square-foot facility and say “in order to remain competitive we need to increase throughput by 30 percent, reduce cost by 15 percent, and still maintain a high level of quality and accuracy.” We will begin by learning about what they’re making, the materials, what machines and tooling they’re using, how the current production line is configured, the degree of automation, and what specific challenges— or “pain points”—they’re struggling with. One thing we encounter a lot these days is volume reduction, where a manufacturer is now making 10 parts instead of 10,000 during a run. In that situation we’d want to make sure their setups and changeovers were as fast and efficient as possible, that they were using the right materials, and that their equipment was versatile enough to allow for a wide range of uses. Another company might be interested in adding a “lights out” night shift, where the machines can run unattended. In that case we would design an intelligent system that would provide live information and even send notifications to smartphones or home computers should someone’s attention be required, and we would make sure those notifications would go to the right person like the production manager or maintenance supervisor. So we don’t provide canned solutions, each one is tailored to meet the customer’s needs. GS: With such a high degree of collaboration, this seems like an academic approach to manufacturing. JE: It really is, and we do work with the Rochester Institute of Technology and Clemson University’s International Center for Automotive Research, or CU-ICAR, where they’re using Okuma machines on projects for their master’s- and doctorate-level programs. So it’s exciting to be in a position to bring all these highly skilled and intelligent people together to the benefit of our customers. Everyone is part of the puzzle that results in our customers achieving their goals and objectives.

To learn More: Call (704) 587-6789 or go online to www.partnersinthinc.com or www.okuma.com.

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The

Mitsubishi

E Series GE

GEAR HOBBERS

GEAR SHAVERS

GEAR SHAPERS

The Truth be Told E Could Stand For: Excellence. Extraordinary. Extreme, etc... and one would be forgiven for thinking so, because these descriptions certainly represent the Mitsubishi machines which contain this letter in their model name. However, the simple truth is that the letter E denotes that these machines are the latest iterations of the models which carry it. The SE gear shapers, GE gear hobbers, FE gear shavers and ZE gear grinders epitomize the development of the process technology they have been designed for and so aptly carry out. Research and Development is not just a glib phrase at Mitsubishi; it is a philosophy that the company stands by to stay ahead of its competition and to ensure continuing profitability and the profitability of its customers. Yes, E could stand for many things but with continuous striving for perfection and intense R & D, the E simply means it is as good as it gets. Period. To personally experience the world-class performance of the Mitsubishi E Series of machines visit mitsubishigearcenter.com or contact sales 248-669-6136.

Machine Tool Division â&#x20AC;˘ Gear Technology Center 46992 Liberty Drive â&#x20AC;˘ Wixom, MI 48393

mitsubishigearcenter.com

GEAR GRINDERS

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