GEAR SOLUTIONS MAGAZINE

 THE EFFECTS OF SHROUDING ON REDUCING MESHED SPUR GEAR POWER LOSS

Your Resource for Machines, Services, and Tooling for the Gear Industry

ISSUE FOCUS

IMTS Show Preview

 THE EFFECTS OF
SHROUDING ON REDUCING
MESHED SPUR GEAR
POWER LOSS
COMPANY
PROFILE

WENZEL AMERICA
AUGUST 2018

AUGUST 2018
gearsolutions.com
 CHUCKS - ARBORS - MANDRELS - COLLETS - FIXTURES

LEADERS in GEAR WORKHOLDING

An Expert In Design and Build

With 70 years of experience, we can handle all your custom workholding needs.
Drewco Corporation is a family run business led by a team of engineers and machinists.
We are backed by original patents, years of experience, and proven effective designs.

service@drewco.com
www.drewco.com Office (262) 886-5050 3745 Nicholson Rd
Franksville,WI 53126
Whatever your needs, we’ve got you covered!
We’re all g-EARS

www.toolink-eng.com

303-776-6212
 Smart.
Gleason non-contact laser
scanning is revolutionizing gear
inspection. Use the GMSL to
speed new gear development,
or take countless hours out of
in-process, high volume gear
inspection with the GRSL. All
supported with precision tooling,
Closed Loop networking, and
application expertise.

www.gleason.com/laser

N-237000 5-C15

© Gleason Corporation. All rights reserved.

2     gearsolutions.com
FEATURES

34
THE EFFECTS OF SHROUDING ON REDUCING
MESHED SPUR GEAR POWER LOSS
Insights from NASA aeronautics rotorcraft research aimed at propulsion
technologies that improve efficiency while minimizing vehicle weight.
By I.R. DELGADO and M.J. HURRELL

AREAL EVALUATION OF INVOLUTE GEAR FLANKS

42 WITH 3D SURFACE DATA
An explanation of how examinations of involute gear flanks using areal, three-
dimensional surface data provides in-depth, holistic information about the gears.
By YUE PENG, KANG NI, and DR. GERT GOCH

MODULAR SEALING SOLUTION IDEAL FOR AUTOMATION

An innovative sealing system has been developed especially for industrial
applications where robustness and long lifespans of gears
are in demand, including robots and automation.
52
By MARCEL SANTOS and BENJAMIN KOHL

A GLOBAL COMPANY WITH A LOCAL FEEL

56 COMPANY PROFILE  Wenzel America is an innovative provider of customized
metrology solutions, built on a solid foundation of German precision engineering
and strong partnerships as a family-owned company.
By GEAR SOLUTIONS

August 2018     3
 Booth N-237106

Manufacturers of:

and Universal Gear Company

1605 Industrial Drive
Auburn, CA 95603
Phone: (530) 885-1939
Fax: (530) 885-8157

4     gearsolutions.com
 AUGUST 2018  •  VOLUME 16, NUMBER 8
DEPARTMENTS
INDUSTRY
8 NEWS
Reports, data, and developments to keep
you aware of what’s happening with your
colleagues in the gear-manufacturing
industry around the country and world.
Klingelnberg engaged in areas of innovation Bourn & Koch to host open house during
at IMTS 2018. IMTS week.

23
In this section, the premier supporter of gear manufacturing in the United American
States and beyond shares news of the organization’s activities, upcoming
educational and training opportunities, technical meetings and seminars, Gear Manufacturers
standards development, and the actions of AGMA councils and committees. Association

MATERIALS TOOTH HOT

28 MATTER 30 TIPS 32 SEAT
MARK MICHAUD BRIAN DENGEL D. SCOTT MACKENZIE

THE STATE OF THE ART A PRIMER ON BACKLASH, ITS HEAT TREATMENT OF POWDER
OF WIND TURBINE GEARBOXES PURPOSE IN GEAR DESIGNS METALLURGY PARTS
Regularly scheduled maintenance Minimizing backlash can create issues Understanding the differences that porosity/
keeps turbines spinning, and the proper with lubrication and encourage excessive density can cause with heat-up times,
lubricants can extend the period between tooth mesh, which can then cause and increased drag-out of quenchants
checkups. premature failure. when processing P/M parts can reduce the
headaches occurring in the heat treat shop.

PRODUCT Q&A
60 SHOWCASE 72
New products, trends, services, and
developments in the gear industry.

RESOURCES
70 MARKETPLACE

71 ADVERTISER INDEX MARC VONDERLAGE

Regional Sales Representative
at Wickert
COVER PHOTO: SHUTTERSTOCK

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 website, which is assumed to be cleared for release. Comments and submissions are welcome, and can
be submitted to editor@gearsolutions.com.

August 2018     5
 FROM THE
EDITOR David C. Cooper
PUBLISHER

Chad Morrison
ASSOCIATE PUBLISHER

IMTS: Bringing the industry together EDITORIAL

Kenneth Carter
T his issue marks our countdown to IMTS 2018, America’s largest manufacturing show.
From September 10–15, manufacturing industry professionals from all across the
globe will be able to see more than 15,000 new machine tools, controls, computers, soft-
EDITOR

Russ Willcutt
CONTRIBUTING EDITOR
ware, components, systems, and processes designed to improve efficiency in practically
every aspect of the industry. More than 2,400 exhibitors are scheduled to display their Jennifer Jacobson
ASSOCIATE EDITOR
products and solutions.
And speaking of solutions, Gear Solutions will be right there in the thick of it.
We like to keep our finger on the pulse of the industry, and there’s no better way to do SALES
that than to be on hand to talk to you about the advantages your business can offer and Chad Morrison
how we can share that with our readers. ASSOCIATE PUBLISHER
Inside this issue, you’ll find a lot of products and services in our Industry News and
Products sections that will be on display at IMTS.
Dave Gomez
REGIONAL SALES MANAGER
But in addition to that, we have several interesting articles to help get you in the mood
for IMTS as well.
An article from I.R. Delgado and M.J. Hurrell discusses insights about NASA aeronau- CIRCULATION
tics rotorcraft research aimed at propulsion technologies that improve efficiency while Teresa Cooper
minimizing vehicle weight. MANAGER
Yue Peng, Kang Ni, and Dr. Gert Goch from the University of North Carolina at Charlotte Jamie Willett
have written an interesting piece titled “Areal Evaluation of Involute Gear Flanks with ASSISTANT
Three-Dimensional Surface Data.”
And Marcel Santos and Benjamin Kohl share their expertise about an innovative seal-
Cole Morrison
ASSISTANT
ing system developed especially for industrial applications where robustness and long
lifespans of gears are in demand.
In this issue, you’ll also hear from some of our regular columnists, and for our two DESIGN
IMTS show issues, the knowledgeable experts from REM Surface Engineering have agreed Rick Frennea
to pen our Materials Matter feature. CREATIVE DIRECTOR
The IMTS clock is counting down, and the show will be here before you know it. I hope Michele Hall
to see you there. I’m excited about seeing old friends and making some new ones. GRAPHIC DESIGNER
As always, thanks for reading!
CONTRIBUTING
WRITERS
I.R. DELGADO
GERT GOCH
M.J. HURRELL
BENJAMIN KOHL
KANG NI
KENNETH CARTER, editor YUE PENG
Gear Solutions magazine MARCEL SANTOS
editor@gearsolutions.com D. SCOTT MACKENZIE
BRIAN DENGEL
(800) 366-2185 x204
MARK MICHAUD
MATT CROSON
Vertical Logo

Coop w
PUBLISHED BY MEDIA SOLUTIONS, INC.
P. O. Box 1987 • Pelham, AL 35124
(800) 366-2185 • (205) 380-1580 fax
David C. Cooper Chad Morrison
PRESIDENT VICE PRESIDENT

Teresa Cooper
6     gearsolutions.com OPERATIONS
FELLOWS 50-8/50-12 GEAR SHAPERS
HYDROSTROKE SHAPERS • REMANUFACTURED IN 2017

Y ea h , w e ’v e got t hat!

We have the world’s largest stock

of used late-model Fellows Gear Shapers.
WE OWN WHAT WE SELL, AND WE KNOW WHAT WE’RE SELLING!

REMANUFACTURED
RETROFITTING
CUSTOM MACHINES
860-223-7778
www.NewEnglandGear.com

343 JOHN DOWNEY DRIVE • NEW BRITAIN, CT 06051-2907 • PHONE 860-223-7778 • FAX 860-223-7776 • JEFF@NEWENGLANDGEAR.COM
August  2018     7
 INDUSTRY
NEWS
Schematic display of the Speed Viper Closed Loop concept (© Image: Klingelnberg)
Klingelnberg engaged
in areas of innovation
at IMTS 2018
IMTS 2018 in Chicago is, according to trade
show organizers, the largest trade show
for manufacturing technology in North
America. Every two years it is the place to
be for the who’s who in the industry. This
year’s trade show will provide a platform
for the newest technology trends. With its
closed loop system for cylindrical gears, a
hybrid solution for optical measurement,
and a digital identification system for tools,
Klingelnberg is now engaged in three areas
of innovation. The solutions provider will
showcase them in the North Building, Level
3, at Booth 236817.
Klingelnberg is presenting the system
provider’s greatest innovations and will
showcase what is possible these days in
terms of digitalization in production. On
that account, the mechanical engineering
company is bringing the cylindrical gear gen-
erating grinding machine Speed Viper 300
SEND US YOUR NEWS Companies wishing to submit materials for inclusion in Industry News should contact the editor,
Kenneth Carter, at editor@gearsolutions.com. Releases accompanied by color images will be given first consideration.
8     gearsolutions.com
NEW TRENDS, SERVICES & DEVELOPMENTS
with KOENIG Automation, the P 40 precision
measuring center (into which the innovative
optical measuring technology, Klingelnberg
Optical Metrology, will first come into use),
and SmartTooling digital tool management
to the stage. Each of these machines and solu-
tions represent the newest, state-of-the-art
of technology and work together in a cyber-
physical production system in which every
step in the value chain is described by a digi-
tal twin. Therefore, Klingelnberg is setting
benchmarks for production in the Industry
4.0 era. In June 2018, the trade magazine MM
Maschinenmarkt just awarded the company
the Best of Industry Award in the Industry
4.0 category.
The Speed Viper 300 is bringing the closed
loop concept into the world of cylindrical
gears. A winner of the iF-Design Award, the
Höfler cylindrical gear generating grind-
ing machine Speed Viper was developed by
Klingelnberg with a very particular focus
on high-production generation grinding in
the large-scale series. To do this, the develop-
ment team has further tested the boundar-
ies of that which is technologically possible
in productivity. With a cutting speed range
of 100 meters/second, the Speed Viper 300 –
which will be exhibited at IMTS – achieves
extremely high productivity.
In doing so, the Speed Viper platform
is optimally designed for the Industry 4.0
manufacturing environment. This most
recent development makes it possible to
connect cylindrical gear machines directly
to the measuring devices. This technology is
already being used successfully in bevel gear
manufacturing. By transferring the closed
loop concept established by Klingelnberg to
the world of cylindrical gears, the mechani-
cal engineering company has made another
systematic step toward digitalization in gear
manufacturing.
Klingelnberg will have a measuring
machine designed for these types of closed
loop processes live at IMTS. The P 40 repre-
sents future-proof quality management of
gears and it showcases Klingelnberg’s new,
ergonomically optimized design. The fully
automatic CNC-controlled precision measur-
ing center is conceptualized as a compact unit
for the workpiece diameter range up to 400
mm. The machine and software concept is
optimized for the measurement of complex
drive components using a technology that
replaces up to six conventional measuring
devices: gear measurement, general coordi-
nate measurement, form and position mea-
surement, roughness measurement, contour
measurement, and optical measurement.
Maximum measuring and reproduction
accuracies are guaranteed – the P series repre-
sents a widely used standard in the industry.
The P 40 that Klingelnberg is presenting at
the IMTS is equipped with a unique feature:
Klingelnberg Optical Metrology.
Klingelnberg has equipped a P 40 with
the new optical measuring technology for
the first time and specially for the trade
show. Klingelnberg Optical Metrology is
a smart combination of tactile and opti-
cal measurement. It combines the benefit
of quick measured value logging using an
optical sensor, with the flexibility and the
extremely high accuracy of the tactile 3D
NANOSCAN sensor system. In this way, the
hybrid system distinguishes itself through
its extremely rapid changeover from the tac-
tile to the optical system and is designed so
that the optical sensors can be adapted in a
number of ways. In addition to this combina-
tion, optical measured value logging alone is
also possible, of course. The measuring result
then takes the form of a high-resolution 3D
point cloud, which can be further processed
and evaluated as a CAD file. The optical
measurement is a new, extremely efficient
option for the precision measuring centers
of the P 26, P 40, P 65, P 100 and P 100L series.
At the IMTS, visitors can see the advantages
of the P 40 demonstrated live.
Also in the company’s “trade show suit-
case”: Digital identification processing
with SmartTooling. With SmartTooling,
Klingelnberg is introducing a digital identi-
fication system for tools and clamping tools,
and is consistently further incorporating
the bevel gear cutting machine into the
Industry 4.0 subject area. With a look toward
an extensive cyber-physical production sys-
tem, it is a case of designing processes that
are currently still carried out manually to
be more efficient using software support
and of establishing the basis for automation.
SmartTooling facilitates traceability and
with it, a 360-degree view of the production
equipment. The additional data that is cur-
rently available also provides a good basis for
the identification of optimization potential
in process improvement. The goal is to sup-
port customers both in reducing costs and
in increasing production quality.
MORE INFO www.klingelnberg.com
AIMS to showcase
advanced CMM
technology at IMTS
Demand for 100 percent part inspection and
the ability to process big data and measure
complex features in a smart factory envi-
ronment is affecting mainstream manufac-
turing. Advanced Industrial Measurement
Systems (AIMS) has engineered coordinate
measurement machines (CMMs) that can
perform fast, accurate inspections and
gather intelligence.
AIMS will demonstrate its Revolution
Series HB Shop Floor CMM fitted with a
Renishaw 5-axis PH20 probe head at Booth
135836 during IMTS 2018.
Visitors can see A IMS’ lab -grade
Revolution Series LM demonstrated at
Renishaw’s Booth 135509. The LM is fitted
THEEMAGVL MACHINES
MAX. PERFORMANCE
GUARANTEED
HIGH FULL
STRENGTH AUTOMATION
COMPACT
VISITUS!
BOOTH S-339436
AIMS Revolution HB Shop Floor CMM. (Courtesy: AIMS)
VERTICAL
with a Renishaw 5-axis REVO 2, which is able MACHINING:
to collect work piece data with 2D and 3D SAFE AND
tactile probes, a surface roughness measure- EFFICIENT
ment probe, or non-contact vision probe.
The HB has a polymer cast base that
includes vibration resistance and thermal
stability. The only 5-axis mobile CMM in
the industry, the HB monitors data process
flow in real time because the PH20 quickly
obtains high-density points for feature size,
Workpiece Workpiece
location, and form for accurate and action- diameter, max. diameter, max.
4 in. 8 in.
able data. The hard bearing machine doesn’t Length, max. Length, max.
6 in. 8 in.
require air and can be moved onto the shop
floor to gather data at the point of use.
The lab-grade LM is built with linear
motors that work off of permanent magnets
that don’t wear out. Electronic signals are
sent to the motor using the natural force of
the magnet to generate a small magnetic field Workpiece Workpiece
diameter, max. diameter, max.
that interacts with the magnets. The result is 12 in. 16 in.
precise positioning and reliability along with Length, max.
10 in.
Length, max.
12 in.
little to no maintenance. The LM has a granite
work plate and aluminum mobile bridge for HIGHLIGHTS
higher rigidity and lower inertia. + Smallfootprint=Reducedfloorspacecost
+ Simple workpiece conveyor & interlinking = Flexibility
AIMS engineers will be available to talk andlowerautomationcosts
about the HB and LM along with the OEM’s + Integratedautomationfornoadditionalcost
total aftermarket support program and ret-
rofit services along with Renishaw MODUS
+ Shorttraversedistances=Minimalidletime,
increasedperformance
software. AIMS will also display custom + Standardizedpartsstrategy=Lowmaintenancecosts
gauging designed and built by CMI, a divi- + Machiningofchuckedparts=Standardizedmachine
platform
sion of AIMS.
+ Operatorfriendly=Quickset-upandchange-over
+ Highenergyefficiency=Reducedenergycost
MORE INFO www.aimsmetrology.com
Bourn & Koch to host
open house during
IMTS week
The global manufacturing community
EMAG L.L.C.
is invited to receive a behind-the-scenes 38800 Grand River Avenue
look into how precision machine tools are Farmington Hills, MI 48335 · USA
Phone: +1 248 477-7440 · Fax: +1 248 477-7784
being built, right here in America, during E-Mail: info@usa.emag.com
www.emag.com
August 2018     9
INDUSTRY
NEWS

the Bourn & Koch “Made in America” open
house on Wednesday, September 12 and
Friday, September 14, 2018.
Tours will be in Rockford, Illinois, at
10 a.m. and 2 p.m. both days of the open
house. Included in the tours will be a dis-
play of select original prints from Blanchard,
Fellows, Springfield, DeVlieg, Bullard, Barber
Coleman, and other brands that Bourn &
Koch, as OEM for 35 American machine tool
brands, is curating.
Full factory tours during the event
include the 130,000-square-foot shop floor
where Bourn & Koch remanufactures classic
American machine tools to OEM specifica-
tions and also builds new Springfield ver-
tical grinders, Blanchard rotary grinders,
Bourn & Koch gear hobbers, Fellows shapers,
and DeVlieg milling machines with the lat-
est technology and designs. A highlight of
the tour will be demonstrations of a newly
redesigned and reengineered Blanchard
22AD-42 rotary surface grinder.
Resident historian, engineer, and Bourn
Bourn & Koch’s Rockford, Illinois, headquarters
includes 130,000 square feet of Made in America
manufacturing capacity. (Courtesy: Bourn & Koch)

& Koch co-founder Loyd Koch, will be greet-

ing visitors during the two-day Rockford
event. Light refreshments and beverages
will be served. RSVP to Tyler Free at Bourn
& Koch: tfree@bourn-koch.com.
Bourn & Koch is in Rockford’s indus-
trial zone, approximately 90 miles from
McCormick Place. For those who cannot
attend the open house during IMTS, other
Polymat series of tour dates are available by appointment
request.
CNC keyseating Bourn & Koch will also be exhibiting at
From simple keyways to IMTS 2018 at Booth #236854 (North building,
machine level 3). The company will be showcasing its
multiple, special profiles, full line of machine tool solutions including
Leistritz Polymat the Springfield VBG vertical grinder, a fully
automated Fellows 10-4 gear shaper, Bourn
and Polyjet & Koch 100H-T turning and hobbing center,
and Blanchard 8AD-12 surface grinder. The
machines have Springfield VBG offers precision grinding
down to 0.0001” as well as integrated verti-
the features cal turning for single-step production and
in-process inspection.
to improve The remanufactured Fellows 10-4 inte-
grates patented electronic crowning and
quality, shorten
taper technology, BKI-S-HMI and Easy
cycletimes and Automate enclosure for standard 3-axis
(or optional 6-axis) CNC gear shaping with
minimize set-ups. Fanuc 0i control. The Fellows 10-4 is an
affordable way for job shops to introduce
high-quality gear manufacturing to their
operations. New to the machine is electronic
helical guide capability. The machine will be
demonstrated with a Halter robot for auto-
loading.
The Bourn & Koch 100H-T gear hob-
ber with seven-station turning turret is
capable of turning, boring, and hobbing
up to AGMA Class-13 gears in one setup to
Leistritz Advanced Technologies Corp.
save floor space, reduce overall cycle times
165 Chestnut Street, Allendale, NJ 07401 and increase workpiece accuracy. Shipped
201 934-8262 with patent-pending Adjustable Hob Arbor
Booth N-237052 www.leistritzcorp.com Spacers and BKI-H-HMI, the machine allows
easy setup, programming and manufactur-
ing by novice operators.
10     gearsolutions.com
 The Blanchard 8AD-12 surface grinder
is an iconic machine tool, producing the
characteristic “Blanchard Grind” synony-
mous with quality ground parts. Like the
Blanchard 22AD-42 being demonstrated at
the “Made in America” Rockford open house,
the smaller Blanchard 8AD-12 in the Bourn
& Koch booth at IMTS is re-imagined and re-
engineered to meet today’s manufacturing
challenges.
MORE INFO www.bourn-koch.com
Sunnen and BTA Heller
create drill-to-finish
bore solution
Sunnen Products Company’s acquisition
of BTA Heller Incorporated has created a
unique solution for shops looking for com-
plete bore drilling-to-finishing capabilities.
Sunnen, the world’s largest vertically inte-
grated manufacturer of honing systems for
precision bore sizing and finishing, adds
BTA’s deep hole tooling and systems for pri-
mary hole generation as the companies build
on natural synergies to offer single-source
bore creation and finishing solutions.
These new solutions will be on display
at IMTS Booth 237400 (Sunnen Products
Company) and Booth 432216 (BTA Heller).
“Our companies complement each other
very well,” said Chris Miltenberger, presi-
dent and COO of Sunnen Products Company.
“No other deep hole/BTA company has
Sunnen’s global presence for customer, tech-

Affolter will display the AF110plus at the Rotec Tools

Ltd. Booth 237223. (Courtesy: Affolter)

Tradition meets
innovation with
Affolter AF110plus
Affolter, founded in 1919 by Louis Affolter
in Malleray, Switzerland, has a long history
of making gears and pinions for the watch
industry. Today the company has more than
160 employees and its market has extended
into medical and aerospace applications.
In 2008, the company started making
gear hobbing machines for medium- and
small-gear applications. Recently, Affolter
introduced the latest design AF110plus
machine, which evolved from the former
AF110 machine. On the AF110plus, a large
range of gears can be produced, such as spur,
helical, face, bevel, crown gears, and worm
screws.
At IMTS 2018, Affolter will display the
AF110plus at the Rotec Tools Ltd. Booth
237223.
Affolter Technology SA celebrates its 100-
year anniversary next year.

MORE INFO www.rotectools.com

August 2018     11
INDUSTRY
NEWS

nical and post-sale support. The transfer of
knowledge between the two companies
will create a unique value proposition, and
Sunnen’s financial stability and strong sales
and service network will deliver this exper-
tise to our customers.”
Sunnen’s core technical competencies
include automated and manual honing
systems, custom system development and
integration, abrasives, tooling, cutting flu-
ids and gaging. The acquisition expands
Sunnen’s industry-leading honing expertise
to include tooling for initial hole creation
and other complementary bore sizing and
finishing processes such as trepanning,
counterboring and form boring. The BTA
Heller product mix includes accessories for
those processes including pressure heads,
vibration dampeners and boring bars.
Sunnen recently introduced the new SHD
series skiving and roller burnishing system
with tooling engineered and supplied by
BTA Heller. Sunnen will also be entering the
market with a deep hole drilling and boring Sunnen/BTA Heller offers an indexable, adjustable
drill head, the Hellerdex, for use in BTA-style deep
hole drilling. (Courtesy: Sunnen BTA Heller)

machine with tooling engineered and sup-

plied by BTA Heller.
“We have developed various tools and sys-
tems for creating intricate internal profiled
deep hole drilling from 0.5 in. to 36 in. diam-
eter,” said Mark Sollich, director of Sunnen’s
BTA Heller division. “To combine forces with
Sunnen and its bore geometry expertise cre-
ates a company not found anywhere else in
our industry. No one company can provide a
total bore solution from the creation of the
primary hole to the final bore finish speci-
fications like we can.”
As Sunnen enters the skiving/roller
burnishing sector, it brings its unique
approach of providing support to custom-
ers also using non-Sunnen equipment, a
key advantage to shops using a variety of
machine types and/or manufacturers for
bore creation and finishing.
“We are able to take an unbiased approach
to achieving high-quality bores,” said
Miltenberger. “We offer solutions based on
drilling, honing, skiving, roller burnishing,
trepanning, or any combination of those.
Choose from one of our portable With our increased product lines and capa-
or laboratory systems, or utilize bilities, however holes need to be made, we
our ISO 170 5 laboratories for can make them.”
accurate and efficient contract
measurement services. MORE INFO www.sunnen.com

For more information contact us at

info@protoxrd.com or 1-313-965-2900
Mitsubishi brings
gear cutting, grinding
technology to IMTS
At IMTS 2018, Mitsubishi Heavy Industries
America, Inc. will be displaying gear cutting
and gear grinding technology designed for
high productivity at Booth N-237036. Using
Super Dry hobbing, the model GE15A gear
LXRD LXRD LXRD iXRD mXRD
STANDARD WIDEBODY MODULAR MAPPING STANDARD ULTRA PORTABLE hobbing machine can also be equipped with
an on-board chamfering station providing
12     gearsolutions.com
LXRD LXRD LXRD iXRD mXRD
STANDARD WIDEBODY MODULAR MAPPING STANDARD ULTRA PORTABLE
multiple processes.
Additionally, MHIA will display the
ZE24B generative gear grinder. Designed
for mass production, the ZE24B has an auto-
matic parts loader and can perform gear
tooth polishing with a single setup using a
compound grinding/polishing wheel.
Both the GE15A hobbing machine and the
ZE24B gear grinder represent Mitsubishi’s
Legendary Reliability in gear manufacturing.
Mitsubishi Heavy Industries America will
display the ZE24B generative gear grinder
at IMTS.
MORE INFO www.mitsubishigearcenter.com
The Mitsubishi Heavy Industries America model GE15A
gear hobbing machine will be on display at IMTS 2018.
(Courtesy: Mitsubishi Heavy Industries America)
Glebar gears up for IMTS
with innovations
in grinding technology
As it enters its 66th year in business, Glebar
is excited to be returning as an exhibitor at
IMTS 2018, North America’s largest manufac-
turers exposition, at Booth 237307.
Representatives will display Glebar’s lat-
est innovations in precision turnkey grind-
ing technology, with a focus on custom-
automated solutions designed and built for
the automotive, medical, metal, and other
markets. From manual to fully automated,
Glebar’s modular GT-610 Series of Infeed/
Thrufeed Centerless Grinders are able to
remove more material faster, and with
better surface finishes, than competing
machines. Configurable modular platforms
and customizable software give it the versa-
tility to design and deliver turnkey solutions
tailored to customers’ pecific needs.
You can view Glebar machines and take a
virtual BoothTour at www.glebar.com; click
on the IMTS 2018 information box.
Also, attendees can register for a VIP booth
appointment where they will be able to speak
one-on-one with a Glebar grinding specialist
to discuss specific application needs.
MORE INFO www.glebar.com
Gleason USA offers
five days of KISSsoft
and KISSsys training
From August 27–31, 2018, Gleason USA
hosts a 4.5 day comprehensive KISSsoft and
KISSsys training which is split into two
parts:
BASIC KISSSOFT TRAINING (2 DAYS)
August 27–28, 2018
This Basic KISSsoft Training covers shaft
and gears and focuses on the usage of the
software and exercises executed by the par-
ticipants. After an introduction to general
settings and some basic theory to develop an
understanding of the technical terms, par-
ticipants will learn about shaft and bearing
functionalities as well as gear design and
optimization strategies including optimal
load distribution and noise reduction.
KISSSYS GEARBOX TRAINING (2.5 DAYS)
August 29–31, 2018
Participants will design a KISSsys model
of an existing bevel-cylindrical-planetary
transmission of 450kW and optimizing the
gears, analyzing the strength of shafts and
lifetimes of bearings as well as efficiency
and contact analysis calculation. Part 1 will
focus on modeling the kinematic structure
of the transmission in KISSsys, part 2 on
dimensioning and optimization by modifi-
cation of the gears, shafts, and bearings.
These courses are suitable for engineers
working in the field of gearbox and trans-
mission calculations and manufacturing.
No advanced KISSsoft software knowledge
is required. Participants may ask for a 30-day
valid test version in order to familiarize
themselves with KISSsoft/KISSsys.
The training will take place at The Gleason
Works Facility in Rochester, New York. Don’t
miss this opportunity and register now.
MORE INFO www.kisssoft.com
August 2018     13
INDUSTRY
NEWS
Methods Machine
Tools announces
key appointments
Methods Machine Tools, Inc., North
America’s foremost supplier of leading-
edge precision machine tools and automa-
tion, has announced two key management
appointments. Company President Jerry
Rex has been named president and chief
executive officer, and Dale Hedberg has
been promoted to vice president of opera-
tions.
Methods’ Board of Directors recently
appointed Rex president and CEO of the
company, after having served as president
during the past year. Rex has been president
of Methods since April 2017 and, before that,
was Methods’ chief operating officer.
“Methods is pleased to appoint Jerry as
president and CEO. With his strong skill
set, machine tool industry knowledge, and
energetic management approach, we are
looking forward to moving the company
ahead through his continued leadership,
positioning Methods as the industry’s lead-
ing supplier of machine tool technology and
OVENS & FURNACES
Large-Capacity Box Furnaces
Temps to 2200ºF/
1204ºC
4-96 cu. ft. capacity
Gas & Electric
models
Lightweight ceramic
fiber insulation
Heavy-duty ceramic
hearth plate
www.grievecorp.com 847-546-8225
14     gearsolutions.com
GRIEVE CORPORATION AD4393j Color
Jerry Rex, president and Dale Hedberg, vice
CEO. president of operations.
automation for our customers throughout
North America,” said Scott McIver, Methods
chairman and third generation owner.
Rex has an extensive amount of machine
tool industry and leadership experience,
including hands-on manufacturing, engi-
neering, sales, and executive management.
He has also served for many years as a mem-
ber of The Association for Manufacturing
Technology (AMT) Board and as Chairman
of the Board of Directors of AMT until April
1, 2016. He has carried the CMTSE designa-
tion since 1997 and remains an active com-
mittee member. His manufacturing career
spans 40 years.
Methods has also announced Dale
1.866.HOB.TOOL
w w w . h o b s o u r c e . c o m
Hedberg has been promoted from director/
national product manager to vice president
of operations. Hedberg is now responsible
for all of Methods’ operations including
production, shipping/receiving, inside sales,
trade shows, and continuous improvement.
A machine tool industry veteran, Hedberg
has been a Methods employee for nearly
20 years in engineering positions, most
recently as product manager for a High
Performance CNC Machining Line.
“Dale’s proven skills for strategically
managing Methods’ product lines and a
deep knowledge of Methods’ infrastructure,
as well as his extensive machine tool experi-
ence, made his promotion to vice president
of Operations a logical one,” said Jerry Rex.
“He will play a key role on our management
team.”
2018 marks the 60th anniversary of
Methods’ founding. To commemorate the
anniversary milestone, Methods will be host-
ing open houses, holding technology events,
and introducing new product lines through-
out the year. Established in November 1958
with three employees and a few refur-
bished machines, Methods has grown
into one of the largest, most innovative,
Performance
Dependability
Value
 ACHIEVE PEAK
PERFORMANCE IN
GEAR GRINDING
TECHNOLOGY

Reishauer sets the standard of technology for continuous

generating gear grinding. Our “Circle Of Competence”
encompasses all aspects of your gear manufacturing success...
machines, automation, tooling, technology & service. Only
one company delivers the peak performance demanded
from today’s competitive gear industry...Reishauer.

1525
Reishauer Holmes Road •| 60123
Corporation (847) Elgin IL, USA |•847.888.3828
888-3828 www.reishauer.com
www.reishauer.com | usa@reishauer.com August 2018     15
INDUSTRY
NEWS
high-precision machine tool suppliers in
North America.
Methods today has about 350 employ-
ees, eight sales and technology centers,
and more than 35,000 machines installed
throughout North America, ranging from
EDM machines to sophisticated 5-Axis CNC
Machining Centers to the latest in robotics
and automation. Methods provides exten-
sive applications engineering support,
installation, parts, service, and training
through a network of large state-of-the-art
technology centers and dealers in North
America.
MORE INFO www.methodsmachine.com
Business growth spurs
hiring at Abtex Corp.,
which adds 4 positions
Abtex Corporation recently added four pro-
fessionals with varied skills in manufactur-
ing and business. The hiring was spurred by
significant recent growth in the company’s
manufacturing deburring business.
RUSSELL,
HOLBROOK &
HENDERSON, INC.
25 E Spring Valley Ave., Maywood, New Jersey 07607
P: 201-226-9000 F: 201-226-9004 E: geartools@tru-volute.com
CELEBRATING 100 YEARS IN BUSINESS
www.tru-volute.com
16     gearsolutions.com
Alfred. He participated in Abtex’s summer
internship program in 2016-2017. Colon lives
in Penn Yan, New York.
Janette Hurley has signed on as an

accounting support associate on Abtex’s
finance team. She was most recently a col-
lections analyst for Xylem Inc. in Seneca
Falls, New York. She is a graduate of Monroe
Community College and lives in Penn Yan,
Rafael Colon Janette Hurley
New York.
Joshua Kinsey has been hired as a manu-

facturing engineer with special responsibil-
ity for the company’s manufacturing prod-
uct line. He recently received his bachelor’s
degree in mechanical engineering, gradu-
ating cum laude from Alfred University.
Kinsey was also an intern with Abtex last
summer and lives in Penn Yan, New York.
Joshua Kinsey Thomas Moracco
Thomas Moracco has joined Abtex as

a mechanical design engineer with special
responsibility for the company’s deburring
Rafael Colon has been hired as a
mechanical design engineer with special
systems product line. He is a recent summa
cum laude graduate from SUNY College
responsibility for the company’s deburring of Technology at Alfred, with a bachelor’s
systems product line. Colon recently received degree in mechanical engineering technol-
a bachelor’s degree in manufacturing engi- ogy. He lives in Waterloo, New York.
neering technology, graduating summa cum
laude from SUNY College of Technology at MORE INFO www.abtex.com
NEW
Release
03/2018
KISSsoft Highlights
▪ Strength calculation of asymmetrical gears
▪ Displacement for bevel and hypoid gears
▪ Interface to GEMS® with data exchange
Booth N-237000 ▪ Shaft editor with background drawing
▪ Calculation of conical compression springs
▪ And many more ...
Precision Gear Products KISSsoft AG/Gleason Sales
Brian P. Stringer
Get your free trial version at
STOCK : HOBS : HSS & CARBIDE Phone (585) 494-2470
STOCK : SHAPERS : Disc & Shank info@KISSsoft.com www.KISSsoft.com
STOCK : MASTER GEARS
RFQ on specials gear tools welcome
Diametral Pitch 12 and finer
STOCK AVAILABLE
 Machinists Inc.
Abtex Corp. promotes FMS Corporation From single
parts to complete
VP of sales/marketing design takes award manufacturing
Jason Saner to president in MPIF contest systems
Abtex Corp., the world’s leading manufac- The winners in the 2018 Powder Metallurgy
turer of machine/brush deburring solutions, (PM) Design Excellence Awards competition, MI cuts gears
has named Jason Saner as president. He will sponsored by the Metal Powder Industries to 250 inches
report to Mark Fultz, Federation (MPIF), demonstrate outstanding in diameter and
Abtex CEO. examples of PM’s diversity. grinds gears to
S a ne r joi ne d The grand prize in the Hand Tools/ 102 inches in
Abtex in June 2013. Recreation category was won by FMS
diameter.
He began as market Corporation for three sinter-hardened steel
development man- parts made for Graco, Inc.: an eccentric gear, a
ager, was promoted combination gear, and a connecting rod that MI provides full
to lead the Systems incorporates a bronze bearing. The parts com- service gearbox
Group in 2014, and prise an assembly that drives a piston pump repair & testing
Jason Saner named vice presi- within a paint sprayer. The complex eccentric for dependable
dent of sales and mar- gear, which is compacted using cored holes overhaul and
keting in 2015. He holds an MBA from the on one side to balance the moment of iner-
enhancement of
University of Rochester’s Simon School and a tia around the center shaft, features AGMA
bachelor’s degree from LeMoyne College. He class 6 gear quality. The combination gear
gear drives.
and his family live in Penn Yan, New York. is complex as well, combining a helical gear
and a spur gear. The bronze bearing is com-
MORE INFO www.abtex.com pacted, sintered, and sized in place inside the
connecting rod, then oil impregnated. The
combination gear and connecting rod are
Jerry Uplinger joins manufactured completely net-shape.

Gasbarre Tooling Group

Winners of the Design Excellence
Awards Competition were announced at the
as design lead POWDERMET2018 International Conference
on Powder Metallurgy & Particulate Materials.
Gasbarre Products, Inc. has announced the
hiring of Jerry Uplinger, tool design engi- MORE INFO www.mpif.org
neer, as the newest member of its Tooling
Group team. He will be the team lead for
tool design efforts Motion Industries
distribution center
at McKee Carbide
Tool.
Uplinger comes
to Gasbarre with
opens near Seattle
many years of expe- Motion Industries, Inc., a leading distribu-
rience in the pow- tor of maintenance, repair, and operation
der metal indus- replacement parts and a wholly owned
try, including his subsidiary of Genuine Parts Company, has
Jerry Uplinger most recent posi- opened the doors for business at its new dis-
tion as tool design tribution center (DC) in Auburn, Washington.
engineer with Metal Powder Products in The facility is managed by Ryan Mort.
Ridgway, Pennsylvania, a position he held The DC’s strategically chosen location fea-
for 16 years. tures easy connections to Interstates 5, 405,
Kevin Snyder, general manager for and 90. It is also conveniently situated 15
Gasbarre Tooling Group, said, “The addition minutes from Sea-Tac International Airport.
of Jerry allows the Gasbarre Tooling Group Covering just over 62,000 square feet, the
to better serve our customers by providing
new tool design. Customers in need of this
DC stocks and ships a broad range of indus-
trial parts and supplies including bearings,
Call us about
service can rely on Jerry’s 30 years of experi- power transmission products, fluid power your project
ence to have a tool set designed around their components, electrical parts, safety sup-
part print.” plies, and more. The new distribution cen- 800 / 244.4130
ter serves 24 area Motion Industries branch
MORE INFO www.gasbarre.com locations daily, as well as the entire Motion www.machinistsinc.com
ISOAugust certified 17
9001 2018     
INDUSTRY
NEWS
Industries North American footprint (550+
locations) as needed.
Joe Limbaugh, Motion Industries VP of
Operations/Distribution/Properties said,
“This is something that our customers have
asked for so we’re happy and excited that
we’re able to fulfill their request.” Limbaugh
said additional enhancements will come
down the road, and looks forward to fulfill-
ing plans for growth.
Motion Industries President & CEO, Tim
Breen, said, “Opening the new DC’s doors
FORGING
AHEAD
OF THE PACK
Fast.
No Fine Print.
No Premium.
At McInnes Rolled Rings, we provide quality
products, shipped fast. And we partner that with
exceptional customer service to forge the perfect
partnership with our customers.
1.877.695.0301  www.McInnesRolledRings.com
18     gearsolutions.com
also means opportunity for our customers
in the region to receive their orders even
quicker. We’re looking forward to deliver-
ing a positive business impact on industry
in the Pacific Northwest.”
The new facility complements Motion’s
primary North American distribution
centers in Birmingham, Alabama; Tracy,
California; Chicago; Baltimore; Dallas;
Edmonton, Alberta; and Lachine, Quebec.
MORE INFO www.motionindustries.com
T.M. Smith Tool adds new Jacobs Taper Rigid ER
Collet Chucks for improved holding power and run
out. (Courtesy: T. M. Smith)
New quick-change
Jacobs Taper Rigid ER
collet chucks
T.M. Smith Tool adds new Jacobs Taper Rigid
ER collet chucks to its family of Jacobs taper
tooling. The new durable collet chucks
are manufactured from premium grade,
through-hardened steel. The Jacobs taper
and ER collet pockets are precision ground
to provide T.I.R. of 0.0002” or better. The T.M.
Smith ER collet chucks are superior to keyed
and keyless drill chucks in concentricity and
holding power.
Available with a Jacobs taper #1, #2, #33
and #4 (JIFFY), these holders are primarily
used in drilling applications. They are com-
patible with standard Jacobs taper spindles
and accept standard ER collets. The chucks
are available in an ER16, ER20, and ER32
option. Specials are always available to
meet customer-specific needs. ER collets are
ordered separately.
T.M. Smith is an industry-leading manu-
facturer of standard and custom toolholding
systems for broad base manufacturing appli-
cations. Established in 1957, the company is
well-known as a pioneer in quick-change
tool holding systems, with a reputation of
high-quality products made in the USA. T.M.
Smith engineers offer decades of experience
and excellent service to customers in a vari-
ety of industries including aerospace, auto-
motive, medical, marine, farm implement,
and machine tool builders.
MORE INFO www.tmsmith.com
Solar Atmospheres option, while being more price competitive 60 YEARS
ON THE
than with a vacuum environment.
acquires large This new investment will complement

CUTTING EDGE
the vast array of large vacuum furnaces that
car bottom air furnace Solar operates every day.

Solar Atmospheres of Western PA has invest- MORE INFO www.solaratm.com

ed in a new car bottom air furnace that is 20
feet in length. Delivery of this new piece of
Then
equipment was scheduled for July, 2018. The
furnace will be surveyed in accordance with Seco Tools names and…
AMS2750 and is uniform within ±10°F (Class
2). The furnace has a working zone that is
Bowden as director NOW
60-inches square by 240 inches long and of information technology
will handle a workload up to 30,000 pounds.
With a maximum operating temperature of Further empowering its customers by con-
1,400°F, this furnace will accommodate not tinuing to advance its digital capabilities,
only the tempering of large tool steel com- Seco Tools, LLC has
ponents but also age hardening of 15-5 PH, announced that Jeff
17-4 PH, and nickel-based alloys. Bowden has joined
Solar is typically known around the t he company as
world as a “vacuum only” heat-treater. its new director of 60 Year s o n t h e
However, there is a great need for heat information tech-
treating non-finished parts and materials nology. In addition Cutting
Southern Eisdcelebrating
Gear & Machine ge
in accordance with the same specifications to his work for the 60 years of leading the way in custom
(AMS, MIL, Boeing and Airbus) within dif-
ferent atmospheres where surface oxidation
is permissible. This new 20-foot air furnace
Jeff Bowden
Nort h A merican
branch of the com-
pany, Bowden will act as the Regional IT
Southern Gear
precision gear manufacturing. Our
ongoing investment in technology and
will allow the “raw material customer” an Demand Manager for Seco Tools AB. Then and ...
personnel NOW
keeps us on the cutting edge
of gear manufacturing, providing the
highest quality gears to the world’s most
demanding industries.

Southern Gear & Machine is celebrating

60 years of leading the way in custom
precision gear manufacturing. Our
ongoing investment in technology and
personnel keeps us on the cutting edge
of gear manufacturing, providing the
highest quality gears to the world’s most

CALL US TODAY TO FIND

demanding industries.

OUT HOW WE
CALL CAN
US TODAYHELP
TO FIND

WITH YOUR PRECISION

OUT HOW WE CAN HELP
WITH YOUR PRECISION
GEARGEAR
NEEDS!
NEEDS!

SOUTHERN GEAR & MACHINE, INC.

3685 NW 106 Street
Miami, Florida 33147
(305) 691-6300
(800) 248-5152
www.southerngear.net
sales@southerngear.net

Cutting Edge Technology in Experienced Hands

Solar Atmospheres’ new car bottom air furnace is 20 feet long. (Courtesy: Solar Atmospheres)
SoGearMarch2017GearSolutions.indd 1 2/20/17 19
August 2018      8:52:41 AM
INDUSTRY
NEWS
“I am very pleased to welcome Jeff Bowden
as part of my management team,” said Rob
Keenan, president of Seco Tools. “I look for-
ward to helping him further integrate IT
into our business strategy as we develop a
true regional hub to support our internal
and external customers.”
Bowden plans to emphasize the impor-
tance of technological growth as demand
for tooling grows in the era of autonomous
manufacturing environments. “Seco Tools
is committed to advancing our capability
Why ETC?
Customer Service, Speed, Quality, & Value
ETC
Choose the stick that works,
cause work doesn’t stop!
2710 West Caro Rd.
Caro, MI 48723
Phone: (989) 673-8733
1307 E. Maple Rd., Suite “G”
Troy, MI 48083
Phone: (248) 619-1616
engineeredtools.com
20     gearsolutions.com
and capacity in this area while we strive
to be on the leading edge of advancements
in technology for the good of the industry
and our customers,” said Bowden. “IT will
act as a partner to all areas of the business,
providing technical expertise and modern
tools that will enable all departments to
work more effectively and efficiently.”
Before joining Seco, Bowden served as the
director for information technology, strat-
egy, processes, and operations for Dassault
Systems. In this role, he spent 16 years
NEW and RECONDITIONED
CUTTER BODIES for Sale.
Engineered Tools Corporation
Complete line of Bevel Gear Tooling
Cutter Body Reconditioning to O.E.M. Specifications
Cutter Body Maintenance Program
Precise Wire EDM Forms for Stick Blades
setting the strategic direction for the IT
organization while managing business rela-
tionships to ensure IT direction remained
aligned with corporate objectives and vision.
Bowden earned his bachelor’s degree
in management information systems
from Oakland University before going
on to receive his MBA at Michigan State
University’s Eli Broad College of Business.
MORE INFO www.secotools.com
KISSsys and GEMS®
working together
in common interface
The GEMS® and KISSsoft programs are now
linked by a single, common interface that
exchanges gear tooth and system design
information between the two software pack-
ages. This data exchange process enables
users to evaluate and optimize all kinds of
bevel and hypoid gears in a realistic way and
with a closed loop between the design pro-
cess and the production software.
KISSsys now also has a new template,
which determines the bevel gear displace-
ments under load. It can be used together
with the interface to GEMS, Gleason’s
bevel gear calculation software platform.
Misalignments are determined on the prin-
ciple of the perpendicular line between the
two shaft axes (pinion and wheel) and can
be displayed with either the E/P/G/Sigma or
the V/H/J/Sigma parameters.
MORE INFO www.kisssoft.ag
Suhner’s redesigned
BEX15 machining unit
picks up more speed
Suhner introduces a new and redesigned
version of its BEX15 machining unit, capable
of allowing a spindle speed increase from
18,000 rpm to 23,000 rpm.
Chip-producing machining operations
with modern tools today demand progres-
sively higher cutting speeds, specifically
for metals with high cutting speed rates or
small diameter hole drilling applications.
The Suhner machining unit type BEX15,
proven in thousands of installations, pro-
vides new speed options, reliably up to the
maximum speed limit. With an increase of
25 percent up to a permissible maximum
spindle speed of 23,000 rpm, operations
requiring higher spindle speeds can be
accomplished more easily.
This improvement is the result of a com-
plete redesign of drive and spindle bearing
components. A new style timing belt drive
multiplies the motor speed up to 13,050 rpm
spindle speed. An AC-inverter drive is used
to increase the spindle speed up to 23,000
rpm at 87Hz.
The BEX15 can be applied in axial and
radial orientation, directly mounted to
a Suhner slide assembly type UA15-PH or
UA15-CNC. In this combination, numerous
machining operations such as milling or
demanding drilling cycles including jump
or peck feed can be easily accomplished.
Four optional tool holder systems (Collet
ER25, ISO30, HSK50 and Weldon), standard
air purge connections for spindle and belt
housing including a number of additional
options (for example, coolant through the
spindle or automated tool change features)
make this machining unit adaptable and an
optimal choice for demanding and specific
machining requirements.
MORE INFO www.suhner.com
Booth N-237024
Class I accuracy
Granite column
Thermally compensated
High capacity table bearing
Linear drives
Motorized tailstock
Universal analysis software
Free unlimited software support
“Closed loop” corrections to production machines
Probe changer
Quick change of tooling
Made in USA
KAPP NILES Metrology | Dayton
The 3-Jaw Chuck ZK 30 “Mini” is made from stainless
steel. (Courtesy: Rotec)
Maprox offers
measuring, precision
fixturing solutions
Maprox specializes in manufacturing com-
pact, low-profile, high-precision jaw chucks
for applications such as metrology, specialty
measuring machines, laser engraving, and
EDM where run-out accuracy and concen-
tricity is of high importance.
PGM 165
PGM 400
info@kapp-niles.com www.gearinspection.com (937) 660-8182
Maprox offers 3-, 4-, 6-, and 8-jaw-chucks.
Many of these chucks are made from mate-
rials such as aluminum, Reinox (non-corro-
sive), non-magnetic or special steel. Jaws are
available in stainless steel, aluminum, brass,
or plastic.
Now offered is the 3-Jaw Chuck ZK 30
“Mini.” This new design 3-jaw precision mini
chuck has a body diameter of 1.18”, clamp-
ing ring 1.30”. Made from stainless steel,
this chuck can be used for EDM applications.
The chuck also has an option with special
pin jaws for small ID clamp (smallest ID
0.08”) and features easy manual handling.
Clamping on the OD is 0.023” to 1.34”
This universal clamping fixture for CMM
machines offers a large variety on clamping
solutions for the most challenging parts. The
modular design includes a 4-jaw chuck (can
be used with 2 jaws), and a basic bore pat-
tern for many clamping options. The 3D-Flex-
Fix consists of a base unit with a set of base
jaws and 4 special pin-jaws with a diameter
of 25mm. The unique clamping mechanism
allows simple, manual clamp of standard
and sensitive components. 
MORE INFO www.rotectools.com
August 2018     21
 Atmosphere Refractory Relines

Are you having difficulty maintaining temperature uniformity in your atmosphere furnace? Have you noticed the
paint peeling on the outer walls of your furnace? Is your refractory cracking, sagging, or falling apart? If so, it
may be time for a refractory reline. Let Ipsen’s experienced atmosphere team help you evaluate your current
refractory conditions and plan your next refractory reline.
With decades of experience, our professional technicians have the knowledge and resources to ensure the
use of proper refractory materials to restore your furnace back to its original condition. Once the reline is
complete, Ipsen can help you reintroduce your furnace to production.

Contact us for your free refractory evaluation:

go.IpsenUSA.com/Retrofits

www.IpsenUSA.com IpsenUSA.com

22     gearsolutions.com Are you going to FNA? Visit us at booth 301.

 American
Gear Manufacturers
Association
Solving ‘The People Impact’:
How can AGMA help?
I
recently completed my 70th tour of a member company, during
which I spent time with AGMA Board Members Michael Engesser
of Reischauer, Cory Ooyen of Global Gear, and Mike McKernin of
Circle Gear. Additionally, I was able to visit with the Meritor engi-
neering team and talk shop with Joe Arvin from Arvin Global Services,
who is an AGMA Distinguished Service Award Winner.
Member tours are great opportunities to hear challenges and oppor-
tunities facing our industry in a direct setting where you can capture
core issues and values quickly and effortlessly since it’s just the two
of you talking one-on-one.
I’m hearing capacity is our issue — companies are giving 110 per-
cent to meet customer expectations as the demand curve swings
almost violently from the extreme downturn of 2014-2016, to a
strong uptick in 2018. It’s not unheard
of to tell a customer you need 11 to 12
weeks over the timeframe they are used
to receiving a gear in … and, I’m hear-
ing of three shifts and companies ask-
ing for capacity help from other local
AGMA members to make gears and com-
ponents for larger systems.
I’m hearing employment is another
issue — finding and retaining operators,
technicians, and other floor personnel
is becoming the priority for AGMA mem-
bers. In fact, in a recent survey conducted
on behalf of the AGMA Foundation, find-
ing and retaining technicians was the primary challenge facing our
industry. In the survey, it didn’t matter what type of company you
were — suppliers, manufacturers, and end users all listed “people” as
the primary challenge facing their companies.
We are on the brink of a major crisis for our industry that I call “The
People Impact,” which is hitting all 482 AGMA member companies.
How many technicians are going to retire in the next five years
from your company?
How many other technician and operator level employees do you
currently need, or forecast to need in the next 18 months?
What is your plan to retain any new employees you hire over the
next year?
How will AGMA help me with this?
The first three questions are yours to answer, but the last one,
AGMA has the following solutions in the works:
AGMA and the AGMA Foundation are committing resources to
develop the Employee Recruitment Toolkit. This marketing kit will
highlight and promote the great things this industry does and pro-
Matthew
Jenny
AGMA
Blackford
Croson
Vice President
president
of
Communications
AGMA
vide your company with materials to use when promoting jobs in our
industry. Materials will include a PowerPoint Presentation, a video,
posters, a brochure, and advertisements that you can add your logo to.
The materials are designed to be used by your company and high-

light jobs you might have. But it also can be used by AGMA staff when
speaking to technical students that will ultimately lead them to our
jobs board on our website. Your membership with AGMA and your con-
tribution to the AGMA Foundation are helping to ensure our industry
gets the employees it needs.
By 2019, AGMA will have developed five new operator level cours-

es. These courses could be part of your internal retention program by
supporting your team members with great training you can’t find
just anywhere. These courses will be at Daley College in Chicago,
making it easy to attend by a majority of
AGMA members — and by sending your
employees to these classes demonstrates
your support in their professional devel-
opment. This is a powerful retention tool
for all companies.
These programs were also developed
by AGMA and the AGMA Foundation.
This is the first time we have developed
programs for operators and is a direct
response to the industry challenges com-
municated by each organization.
Big Picture: AGMA and its Foundation
are allocating money directly toward the
industry’s primary challenges, as described by 467 individuals who
participated in our survey in 2017 and approved by both the AGMA
and AGMA Foundation boards.
Small Picture: AGMA and its Foundation are developing tools that
can be leveraged by the industry to both attract new employees and
to retain the ones you’ve hired.
What’s in it for me? Picture: Your direct support of AGMA and its
Foundation means you have tools to help your company grow and be
sustainable.
These new programs add value to the existing 13 different face-to-
face engineering level classes, the Fall Technical Meeting, the Annual
Meeting, and other events AGMA holds during the year. All of them
are designed to keep your team up-to-date on emerging technologies,
industry trends, and the latest news, and your active participation in
each event ensures you are getting to network with the right people.
AGMA is here to help the industry thrive, and working closely with
our members, we are on a path that directly responds to current indus-
try challenges.
August 2018     23
2018 Fall Technical Meeting

Attendees at the 2017 FTM.

F
or more than 30 years, AGMA has been hosting a technical conference to high- PRICING DETAILS
light the newest emerging technology in the gear industry. The Fall Technical
Meeting (FTM) is the top place to learn about the latest research in the gear indus- EARLY BIRD REGISTRATION
try from the researchers directly. Each year, the FTM provides an outstanding (JUNE 5–AUGUST 24)
opportunity to share ideas with others in the gear industry on design, analysis, manu- Member: $950.00  |  Non-Member: $1,250
facturing, and application of gears, gear drives, and related products, as well as associ-
REGULAR REGISTRATION
ated processes and procedures. Attendees get a chance to be on the cutting edge of gear
(AUGUST 25–SEPTEMBER 23)
research and network with other engineers.
Member: $1,050  |  Non-Member: $1,350
Each speaker will present the content of his or her technical paper that has gone
through a double-blind peer review of three industry topic experts. All papers presented ONSITE REGISTRATION
at FTM will be indexed in Scopus, the international database of peer-reviewed literature. Member: $1,100  |  Non-Member: $1,400
Come see why this popular event is growing year after year and be a part of a technical
community that is always striving to improve and grow the gear industry. SINGLE SESSION
Member: $295  |  Non-Member: $395
NEW EVENT AT FTM: BOWLING & BOCCE NETWORKING RECEPTION
BOWLING & BOCCE NETWORKING
AGMA has added an extra evening of networking and fun to the FTM. Sponsored by Scot
RECEPTION
Forge, FTM attendees who purchase a ticket for $50 can attend an evening full of bowl-
Member & Non-Member: $50
ing, bocce, and great conversation with their gear-industry peers. Dinner and open bar
is included with your ticket at the Pinstripes in Oak Brook. Please visit the Pinstripes
website to get a look at what to expect.

American
Gear Manufacturers
Association
24     gearsolutions.com
Location of the Bowling & Bocce Networking Reception in Oak Brook. Attendees at the 2017 FTM.

Upcoming Courses
Don’t forget! AGMA education courses are IACET accredited. This means the courses you take through AGMA will earn you
continuing education units. Choose gear education that does more for you!

BASIC TRAINING FOR GEAR MANUFACTURING
(2.67 CEUS)
SEPTEMBER 11-14, 2018 | CHICAGO, ILLINOIS
Learn the fundamentals of gear manufacturing in this hands-on
course. Gain an understanding of gearing and nomenclature, prin-
ciples of inspection, gear manufacturing methods, hobbing and shap-
ing. Using manual machines, develop a deeper breadth of perspec-
tive and understanding of the process and physics of making a gear,
as well as the ability to apply this knowledge in working with CNC
equipment commonly in use.
FUNDAMENTALS OF WORM & CROSSED AXIAL HELICAL
GEARING (1.3 CEUS)
SEPTEMBER 20-21, 2018 | ALEXANDRIA, VIRGINIA (COME TO
AGMA HEADQUARTERS)
Provides an introduction and emphasizes the differences between
parallel (the experience base) axis and worm and crossed axis helical
gears. Describe the basics of worm and crossed axis helical gears,
their fundamental design principals, application guidelines and rec-
ommendations, lubrication requirement, a discussion of accuracy and
quality, and summarize with a brief review of common failure modes.
EPICYCLIC GEAR SYSTEMS: APPLICATION, DESIGN
& ANALYSIS (2.0 CEUS)
SEPTEMBER 27-29, 2018 | ROSEMONT, ILLINOIS
Learn and define the concept of epicyclic gearing, including some
basic history and the differences among simple planetary gear systems,
compound planetary gear systems, and star drive gear systems. Cover
concepts on the arrangement of the individual components, including
the carrier, sun, planet, ring, and star gears and the rigid requirements
for the system to perform properly. Critical factors such as load sharing
among the planet or star gears, sequential loading, equal planet/star
spacing, relations among the numbers of teeth on each element, and
calculation of the maximum and optimum number of planet/star gears
for a specific system will be covered. Provides an in-depth discussion
of the methodology by which noise and vibration may be optimized for
such systems and load sharing guidelines for planet load sharing.

AGMA has over 1,000 Twitter followers! Join the conversation @agma

1001 N. Fairfax Street | Suite 500 | Alexandria, VA 22314 | (703) 684-0211 | www.agma.org
August 2018     25
 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, AGMA has something to offer you. If you would like more information on any of the
following events, visit www.agma.org or send an email to events@agma.org.
AUGUST

August 10 — Emerging Technology Committee Meeting — WebEx

August 10 — Plastics Committee — WebEx
August 14 — Helical Gear Rating Committee — WebEx

September 4 — Wind Turbine Gear Committee — WebEx

September 5 — Nomenclature Committee — WebEx
SEPTEMBER

September 6 — Lubrication Committee Meeting — WebEx

September 7 — Flexible Couplings Committee — WebEx
September 11 — Helical Gear Rating Committee — WebEx
September 13 — Metallurgy and Materials Committee — WebEx
September 14 — Fine-Pitch Gearing Committee Meeting — WebEx
September 18 — Gear Accuracy Committee — WebEx
September 20 — Wormgearing Committee — WebEx
OCTOBER

October 3 — Nomenclature Committee — WebEx

October 4 — Lubrication Committee Meeting — WebEx
October 18 — Fine-Pitch Gearing Committee Meeting — WebEx
October 30 — Gear Accuracy Committee — WebEx

AGMA LEADERSHIP

Jim Bregi: Chairman Michael Engesser: Reishauer Corporation

EXECUTIVE COMMITTEE

Doppler Gear Company

Bent Hervard: CFT
John Cross: Treasurer
ASI Technologies Inc. David Long: Chalmers & Kubeck Inc.
BOARD OF DIRECTORS

Greg Schulte: Chairman, BMEC Michael McKernin: Circle Gear and Machine Company
Bonfiglioli USA.
Todd Praneis: Chairman, TDEC Scott Miller: Caterpillar, Inc.
Cotta Transmission Company, LLC Gary Neidig: ITAMCO
Dean Burrows: Chairman Emeritus
Gear Motions Inc. Shawn O’Brien: McInnes Rolled Rings
Cory Ooyen: Global Gear & Machining, LLC
Matt Croson: President
Carl D. Rapp: The Timken Company
Amir Aboutaleb: Vice President, Technical Division
STAFF

Jenny Blackford: Vice President, Marketing Tania Sabados: Rapid Gear

Jill Johnson: Director, Member Services George Thomas: Bison Gear & Engineering Corporation
Casandra D. Blassingame: Director, Education Hastings Wyman: Klingelnberg America, Inc.
General requests: webmaster@agma.org | Membership questions: membership@agma.org | Trade show information: blackford@agma.org
Technical/Standards information: tech@agma.org | AGMA Foundation: foundation@agma.org
26     gearsolutions.com
 Booth #
237024
Revolutionary, Robust and Rewarding Solutions! North, level 3

we’re getting ready for IMTS2018 and can’t wait to see you at our booth!

ZE 800 profile grinding

KNe3G generating grinding

KNM 2X analytical gear inspection

KAPP Technologies kapp-niles.com info@kapp-niles.com (303) 447-1130

August 2018     27
 MATERIALS MARK MICHAUD
MATTER
TECHNIC AL FELLOW   
  REM SURFACE ENGINEERING
The state of the art of wind turbine gearboxes
Regularly scheduled maintenance keeps turbines
spinning, and the proper lubricants can extend
the period between checkups.
M uch has been written here about the global growth in the wind
turbine industry. Today, more than 341,320 wind turbines are
operating worldwide. In particular, the number of offshore installa-
tions has exploded in the past seven years (Figures 1-2).
The continuous reliability gains in the industry have caused cost
of wind turbine electricity to drop significantly, so much so that
some current offshore projects are under way without any govern-
ment subsidy, with full understanding of the unique maintenance
issues and costs associated with offshore installations. This momen-
tum is proof of how far wind turbines have come in terms of reli-
ability and cost effectiveness.
TIME BETWEEN MAINTENANCE: LUBRICANT
In regard to the wind turbine gearbox, gone are the epidemic fail-
ure rates of fewer than three years seen in the early 2000s. Rather,
today’s gearbox normally requires a major scheduled maintenance
only after seven to 10 years, typically for bearing replacement. And
remember, this is a scheduled maintenance, not a replacement of a
failed gearbox.
Unfortunately, the wind turbine gearbox lubricant and filtration
system has not achieved a similar increase in durability. A maximum
of three to five years is the typical life expectancy for the lubricant, and
even less for the lubricant filters. As a result, major efforts are under
way to increase the life expectancy of the lubricant. Approaches such
as improved filtration, lower lubricant operating temperatures, and
newer formulations have all been and continue to be studied in this
effort. The goal is to increase the time between maintenance for the
lubricant to match or exceed that for the gearbox.
In particular, lubricant debris generated from the gear teeth dur-
ing start up and operation is a major cause of lubricant deteriora-
tion. Despite all the improvements in gear design and manufactur-
ing, wind turbine gear teeth continue to rub (i.e. operated in mixed
EHL) and release hard iron metal particles into the lubricant. These
Figure 1: Installed global wind capacity in megawatts (above). Figure 2: Cumulative offshore capacity in
megawatts (right). (Global Wind Energy Council)
28     gearsolutions.com
metal particles rapidly clog the filters if they are large enough to
be captured. Unfortunately, many are too small to be filtered out.
These unfilterable small particles, typically 1-5 microns in size, cre-
ate numerous lubricant problems. For instance, very large pressure
peaks are produced when a small hard metal particle passes through
the contact zone of a gear or bearing, as represented in Figures 3-4.
Along with denting or abrading the tribological surface of the given
component, which leads to a further increase in mixed EHL, the
particles result in high pressure peaks which accelerate the sur-
face fatigue of the gear or bearing. In fact, some experts believe the
high pressure peaks from metal particles in bearing contacts lead
to or contribute to the problem of axial fatigue cracking in today’s
wind turbine industry (T. Stalin; Vattenfall; NREL/GRC presentation
February 2018).
Further problems develop when small iron particles combine with
other lubricant materials to form large, soft conglomerates. These
conglomerates accelerate the clogging of the filters. And remember,
once the filter is clogged, the filter bypass automatically opens and
all filtration is lost until the filters can be changed.
Also, small metal particles in the presence of the high lubricant
operating temperatures are catalysts for numerous deteriorating
side chemical reactions. In particular, water in the high tempera-
ture lubricant, down to even 100 ppm, is an excellent ingredient to
react with iron particles and some of the special lubricant additives.
Many wind turbines are operating with 1-2 percent water content in
their lubricant along with >1,000 ppm of small iron particles. This
is an excellent incubator for deteriorating chemical side reactions.
A NEW APPROACH
It is understandable that wind turbine lubricant filtration, lower-
ing operating temperatures, and new formulations have gotten
the initial industry focus to increase the time between lubricant
maintenance. Much has already been accomplished in these areas,
but there are limits that these approaches can accomplish and most
improvements have already been achieved.
A different approach has been proposed and its study has begun.
Rather than accepting the problems associated with the teeth gen-
erating hard iron particle debris, the goal is to eliminate the tooth
debris altogether. This approach is using
the ISF® process to superfinish all the gears
throughout the gearbox.
Historically, isotropic superfinishing has
been applied only to the input stage of a wind
turbine gearbox such as the annulus, sun pin-
ion, and planets. These are the slowest moving
and highest loaded gears and experience the
most amount of surface distress. Commercial
experience since 2003 has proved that isotro-
pic superfinished wind turbine gears do not
develop surface distress, even after many
years of operation. So it is expected that fully
isotropic superfinished wind turbine gear-
boxes will achieve the same result.
Figures 5-6 depict a set of multi-mega Figure 3: Schematic of a contact zone containing a hard metal particle and its resulting pressure peak.
wind turbine planets that were originally
isotropic superfinished by the manufacturer.
The “galvanized” tooth surface appearance is the normal burnished
appearance. These planets had been removed after seven years of Rather than accepting the problems
operation for bearing maintenance and were returned to operation
without any repair. Note there is no metal to metal contact pattern
associated with the teeth generating
on the tooth flanks. This is proof that these isotropic superfinished
planets were, and are continuing to operate, in full EHL. In other
hard iron particle debris, the goal
words, the planet teeth are not rubbing against the sun pinion or is to eliminate the tooth debris
annulus teeth and no iron particle debris is being generated.
altogether.
SUMMARY
The new study will use a series of gearboxes where all the gears are to continue operating indefinitely and the condition of the lubricant
isotropic superfinished. These gearboxes will be placed in operation will be monitored.
and carefully monitored for particle debris generation. After a period Hopefully, the lubricant will remain fully operational for seven or
of time, if all goes well, the original filters will be upgraded with more years and the time between maintenance for the gearbox, its
finer particle filters to remove even the smallest particle of debris. lubricant and filter will be extended and balanced. This study will
(Remember, even 1 micron particle debris can damage the bearings take many years to complete. Periodically, progress reports will be
in a wind turbine gearbox.) Then the wind turbines will be allowed published to the wind turbine industry on this effort. 

Figure 4: Image of the pressure peak caused by a Figure 5: Three multi-megawatt class isotropic Figure 6: Closeup of the top planet after seven years
hard particle in a contact zone. superfinished planets removed after seven years of showing no metal to metal contact pattern.
operation.

ABOUT THE AUTHOR

Mark Michaud, technical fellow at REM Surface Engineering, is a leading expert in the field of isotropic superfinishing of engineered metal
components. During his 35-year career at REM he has worked in research, operations, sales, and management. Michaud has been granted more
than 100 patents, published numerous technical articles, and given lectures in the United States, Europe, and Asia. He has degrees in chemistry
from Reed College and an MBA from the University of Hartford. He can be reached at mmichaud@remchem.com. Also visit www.remchem.com.

August 2018     29
 TOOTH BRIAN DENGEL

TIPS GENER AL MANAGER   KHK-USA

A primer on backlash, its purpose in gear designs

Minimizing backlash can create issues with
lubrication and encourage excessive tooth mesh,
which can then cause premature failure.
I f gears are designed with a standard tooth proportion and are oper-
ating on a standard center distance, they would mesh ideally and
would neither jam or require backlash. Unfortunately, gears, like
life, are never ideal.
The general purpose of backlash is to prevent gears from jam-
ming due to contact occurring on both sides of the tooth at the
same time. A minimal amount of backlash is important in order
to allow a space for lubricant to enter the mesh and also allows for
any thermal expansion of the gearing under load. Manufacturing
errors, including errors in profile or pitch or tooth thickness or helix
angle or even center distance, all contribute to the need for backlash
allowances. Gears produced with very small total composite error or
tooth-to-tooth errors can have a smaller backlash allowance because
the errors that need to be compensated for are less. Figure 1
On the other hand, having a very large amount of backlash in
the mesh is not ideal if you are operating a reversing drive, as the between the increase in center distance and the linear backlash
positioning of the driven gear will vary greatly over time. along the line of action is as follows:
In order to obtain the desired backlash, it is necessary to reduce
jn = 2 Da • sin(a)
the tooth thickness of each gear in the mesh. The decrease in tooth
where:
thickness is usually greater than the amount of backlash desired,
as manufacturing methods will introduce error that will vary the Da is the change in center distance
thickness. It is also common practice to have half of the backlash a is the pressure angle
allowance applied to the tooth thickness of each gear in mesh. In the
case of bevel gears, where the pinion has very few teeth compared to The equivalent linear backlash along the pitch circle is defined as:
the mating gear, all of the backlash allowance is applied to the larger
j = 2 Da • tan(a)
gear in order to maintain the maximum strength of the pinion.
As detailed in the Figure 1, backlash is defined as the excess thick- The relationship of backlash is dependent primarily on the pres-
ness of the tooth space over the thickness of the mating tooth. The sure angle and is independent of pitch. From this relationship, it can
two conditions that contribute to backlash are when either the tooth be derived that 20-degree gears have a 41 percent greater backlash
thickness is below the zero-backlash value or if the operating center than 14.5-degree gears.
distance is greater than the zero-backlash value. There are four types of backlash: circular backlash, normal back-
If the tooth thickness of either of the mating gears is less than lash, center backlash, and angular backlash. The angular backlash
the zero-backlash value, the amount of backlash is simply as follows: of the gear shaft is usually the critical factor in most gear designs.
As this value is inversely proportional to the gear radius and since
j = sstd - sact = Ds
the two gears in mesh are usually of different pitch radii, the linear
where: backlash at the pitch circle converts to different angular values for
j is the linear backlash measured along the pitch circle. each gear in mesh. As such, the angular backlash of each gear must
Sstd is the standard tooth thickness for ideal gears (also no back- be specified to a specific gear center.
lash tooth thickness on the operating pitch circle). Many designers try to minimize the backlash the gear manufac-
Sact is the actual tooth thickness. turer builds into each gear by assembling the gears with a reduced
When the center distance is increased by a relatively small center distance. This is not desirable, as it eliminates the space for
amount, a backlash space develops between the mating teeth that lubrication to function, and it encourages excessive tooth mesh,
can cause excessive noise or premature wear. The relationship which in turn causes premature failure of the mesh. 

ABOUT THE AUTHOR Brian Dengel is general manager of KHK-USA, which is based in Mineola, New York. Go online to www.khkgears.us

30     gearsolutions.com
Gear Technology and Automation Systems.

Visit us at:

IMTS 2018
September 12 - 17
Chicago, USA
North Hall, Booth 236914

Connecting systems for intelligent production!

Gear Shaping Machine LS 400 EM: Maximum flexible shaping machine
Enlarged workpiece diameter up to 400 mm
Moveable and electronic shaping head

Gear Grinding Machine LGG 400 M: Generating, profile and internal grinding
Extended work area for shaft-applications
Grinding Head with adaptable internal grinding arm

Bin Picking Work Station: With new camera-based vison system

Turnkey solution – cell, robots with additional 7/8-axis, grippers, vision system, and software
Three different vision systems are available to optimize your application: fast, accurate and robust

Robot Application: Flexible robot cell

Cost-effective cell for multi-purpose part handling
Modular design for expedited engineering

Liebherr-LinkedIn Liebherr-Twitter Liebherr-Youtube

https://go.liebherr.com/ https://go.liebherr.com/ https://go.liebherr.com/
4Dk433 T92xu7 QDydxV

Liebherr Gear Technology, Inc.

1465 Woodland Drive
Saline, Michigan 48176-1259
Phone.: +1 734 429 72 25
E-mail: info.lgt@liebherr.com
www.liebherr.com August 2018     31
 HOT D. SCOTT MACKENZIE, PH.D., FASM
SEAT
SENIOR RESEARCH SCIENTIST–METALLURGY  
HOUGHTON INTERNATIONAL INC.
Heat treatment of powder metallurgy parts
Understanding the differences that porosity/
density can cause with heat-up times, and
increased drag-out of quenchants when
processing P/M parts can reduce the headaches
occurring in the heat-treat shop.
T he use of powder metallurgy (P/M) for the production of near-net
shaped parts has increased in recent years due to performance
gains, as well as the advantage of producing a near net shape. P/M
is not one single process, but a description of processes that start
with metal powder as a feed stock. This can include traditional press
and sinter, metal injection molding (MIM), powder forging, and hot
isostatic pressing (HIP). Additive manufacturing can also be consid-
ered a powder metallurgy process, as the process starts with a metal
powder as a feedstock.
There are significant differences between heat treating a conven-
tional steel part and a P/M part. Porosity, composition, and homoge-
neity are the primary sources of differences between the heat treat-
ment of a wrought steel part and its P/M counterpart. Understanding
the differences allows the heat treater to compensate to achieve a
part of consistent properties.
Focusing on traditional press and sintering P/M operations, since
it is the most commonly encountered, the metallic powders of the
desired alloy are blended together. Additives, such as lubricants and
binders, are added to the mix to increase
green strength and reduce die friction. Once
the powders are properly blended, the parts
are then compacted to form the green part.
Compaction is the most critical step
since the proper compaction process estab-
lishes the density of the green compact; the
strength of the green compact; as well as
the homogeneity of the green part. Final
properties after heat treatment depend
strongly on the density of the part. Uniform
properties require a uniform distribution of
density. Mechanical or hydraulic presses are
used along with rigid tooling to achieve the
desired green compact.
One additional consideration of compac-
tion is the mechanical strength of the green
compact. It must be strong enough to resist
the mechanical forces during the ejection
process, as well as handling through the
sintering process. In general, if the part can
withstand the ejection process, it is strong
enough for subsequent handling.
The properties of P/M parts are strongly Figure 1: Schematic of tradition press and sinter P/M during densification or non-uniform heat-
dependent on the density of the part. The parts. [1]
32     gearsolutions.com
 
density of the part is dependent on the pressure used, as well as the
characteristics of the powder. During compaction, movement of the
powder occurs, with the powders rearranging to fill available space.
Deformation of the powder can occur, as well as the powder par-
ticles breaking or fragmenting. The type of powder and alloy governs
what mechanism occurs. Brittle or ceramic powders tend to fracture;
elemental powders (iron, nickel and copper) will tend to deform.
Highly alloyed powders will usually be between these two extremes.
Once the part has been compacted, and ejected, the part is sin-
tered. Sintering involves placing the parts in a controlled atmosphere
and heating them. Sintering is often accomplished using a mesh
belt furnace or pusher furnace. If higher tem-
peratures are needed, then vacuum furnaces
are used. A purge is performed to reduce the
amount of combustible atmosphere present
and to remove any binders present by vola-
tilization. The temperature is increased to
approximately 75 percent of the melting
temperature to allow solid state diffusion to
occur. Adequate time at temperature is nec-
essary to allow solid state diffusion to form
adequate strength bridging bonds across the
particles, and to form proper metallurgical
bonding of the particles. Additional time
during sintering increases part density by
reducing the number and size of pores. The
part is then cooled under the protective
atmosphere. The protective atmosphere
can be a vacuum or argon and 10 percent
hydrogen. Other atmospheres are also used
to reduce the formation of metal oxides at
the particle interfaces.
Compaction usually sets the dimensions
of the part. However, distortion can occur
ing or cooling. Repressing or coining is often
 90
1080 High
80
1080 Low
70
Apparent Hardness (HRA)
60
50
40
30
0 1 2 3 4 5 6 7
Distance from Quenched End (mm)
Figure 2: Reduced hardenability of P/M steels. [2,3]
used to correct dimensions. This process can also increase the density
of the part.
A schematic of the P/M process is shown in Figure 1.
HEAT TREATMENT OF P/M PARTS
The primary differences in the heat treatment of P/M parts from
their wrought counterparts are related to the density of the part.
High density parts (greater than 90 percent) can generally be consid-
ered to be similar to wrought products, and processed accordingly.
However, should the density deviate below 90 percent, then the parts
would be processed differently.
General considerations for heat treating P/M parts:
Surface damage. Since P/M parts are designed to be net-shape
and avoid machining, and sort of nick or surface damage can reduce
acceptance.
Residual Fluids. Parts that have had secondary operations prior
to heat treatment may have residual fluids present that are being
held in the pores of the P/M part. These residual fluids can affect
part surface quality and potentially reduce part strength during heat
treatment. Washing and rinsing with the proper cleaner is necessary.
Loading during Heat Treatment. Like wrought parts, the loading
or racking is critical to achieve a low distortion part. Proper racking
ensures that proper quenchant and gas flow are achieved around the
part. It also ensures the parts are properly heated to the austenitizing
temperature.
Drag-Out of Quenchant. Because of the porosity present in P/M
parts, the quenchant can penetrate these pores. A proper cleaning
step, usually containing multiple cleaning operations, is often neces-
sary. This also reduces drag-out of the quenchant to the tempering
operation, with resultant fumes.
Induction Hardening. If water or aqueous quenchant is used, rust
can form on the surface and interior of the parts. The use of quen-
chants with a suitable corrosion inhibitor is recommended. Further
a drying operation in addition to the tempering operation may be
required.
Quenchants. The hardenability of P/M parts is lower than similar
chemistry wrought parts. This is due to the reduced thermal diffusiv-
ity of the P/M part. The reduced thermal diffusivity is the result of the
ABOUT THE AUTHOR D. Scott MacKenzie, Ph.D., FASM, is senior research scientist-metallurgy at Houghton International Inc. For more
information, go to www.houghtonintl.com.
reduced density of the part. This reduced thermal density requires
a faster quenchant than would normally be required for a similar
chemistry wrought product.
The porosity present in P/M parts results in lower density and
lower thermal diffusivity. This results in a lower hardenability
(Figure 2).
7.1 g/cm3
In this figure, a series of Jominy tests at different densities were
6.8 g/cm3 compared to the wrought equivalent. The densities ranged from 9 to
24 percent. This showed that, not only was the hardenability reduced
6.4 g/cm3
due to the increased porosity, but also the apparent hardness was
reduced.
6.0 g/cm3 The lower thermal diffusivity increases the time to heat-up to
temperature. This means that a mesh belt furnace designed for one
load of wrought parts, will have to be drastically derated to achieve
8 9 10 the proper heat up time for P/M parts. A model showing the relation
of porosity to thermal diffusivity is:
l= lm (1 - 2e)
Where l is the theoretical conductivity of the P/M part, lm is the
conductivity of a fully dense material, and e is the fractional density
of the part. This reduction in the thermal diffusivity means that it
takes much longer for a part to heat to the desired austenitizing
temperature.
P/M parts are typically quenched in water, brine, aqueous polymer
quenchants, and oils. The water-based quenchants are faster than the
oil quenchants, but may accelerate corrosion due to residuals trapped
in the pores of the part. Oil quenching is typically less severe and is
used to reduce distortion and cracking. Because of the low thermal
diffusivity and hardenability of P/M parts, a fast oil (typically about
9 GMQS) is usually used.
P/M parts will absorb about 2-3 percent oil by weight. During the
tempering operations, this can result in smoke and fumes in the
temper furnace. If the oil buildup is excessive, then oil fires can (and
will) occur. The higher drag-out of oil needs to be considered during
processing. Typically, quench tanks are sized to quench one gallon
of parts to one gallon of oil to keep the temperature low. For P/M
parts, the load is usually sized for 3-4 gallons of oil for every pound of
parts. This is due to the slower heat-up of P/M parts and the amount
of drag-out occurring.
CONCLUSIONS
Understanding the differences that porosity/density can cause
with heat-up times and increased drag-out of quenchants when
processing P/M parts can reduce the headaches occurring in the
heat treat shop when processing P/M parts. Additional discussions
regarding case hardening and induction hardening will follow in
a later column. 
REFERENCES
[ 1 ] Ferguson, H. (1975). Metals Progress, 107(6), 81-83.
[ 2 ] Ferguson, H. (1975). Metals Progress, 108(2), 66-69.
[ 3 ] Newkirk, J. W., & Thakur, S. N. (2007). Heat Treatment of Powder Metallurgy
Steel Components. In G. E. Totten (Ed.), Steel Heat Treatment (pp. 741-
788). Boca Raton, FL, USA: Talyor and Francis.
August 2018     33
ISSUE IMTS SHOW PREVIEW
FOCUS

THE EFFECTS OF
SHROUDING ON REDUCING
MESHED SPUR GEAR
POWER LOSS

Printed with permission of the copyright holder, the American Gear Manufacturers Association, 1001 N. Fairfax Street, Suite 500, Alexandria,
Virginia 22314. Statements presented in this paper are those of the authors and may not represent the position or opinion of the American Gear
Manufacturers Association. (AGMA) This paper was presented October 2017 at the AGMA Fall Technical Meeting in Columbus, Ohio. 17FTM04

34     gearsolutions.com
Insights from NASA aeronautics rotorcraft research
aimed at propulsion technologies that improve
efficiency while minimizing vehicle weight.
By I.R. DELGADO and M.J. HURRELL
G
earbox efficiency is reduced at high rotational
speeds due to windage drag and viscous effects
on rotating, meshed gear components. A goal of
NASA aeronautics rotorcraft research is aimed
at propulsion technologies that improve efficiency
while minimizing vehicle weight. Specifically, reduc-
ing power losses to rotorcraft gearboxes would allow
gains in areas such as vehicle payload, range, mission
type, and fuel consumption. To that end, a gear windage
rig has been commissioned at NASA Glenn Research
Center to measure windage drag on gears and to test
methodologies to mitigate windage power losses.
One method used in rotorcraft gearbox design
attempts to reduce gear windage power loss by utiliz-
ing close clearance walls to enclose the gears in both
the axial and radial directions. The close clearance
shrouds result in reduced drag on the gear teeth and
reduced power loss. For meshed spur gears, the shroud-
ing takes the form of metal side plates and circum-
ferential metal sectors. Variably positioned axial and
radial shrouds are incorporated in the NASA rig to
study the effect of shroud clearance on gearbox power
loss. A number of researchers have given experimental
and analytical results for single spur gears, with and
without shrouding.
Shrouded meshed spur gear test results are sparse in
the literature. Windage tests were run at NASA Glenn
using meshed spur gears at four shroud configurations:
unshrouded, shrouded (max. axial, max. radial), and
two intermediate shrouding conditions. Results are
compared to available meshed spur gear power loss
data/analyses as well as single spur gear data/analyses.
Recommendations are made for future work.
INTRODUCTION
Rotorcraft gearboxes are critical in efficiently trans-
ferring power from the turboshaft jet engine to the
main and tail rotors for conventional helicopters.
Efficiencies of 95 to 97 percent are common [1], and
they are also used in fixed wing aircraft such as
geared turbofans and the VTOL (Vertical Take-Off and
Landing) V-22 Osprey. With ever-increasing fuel costs
for air transportation, research is focused on demon-
strating and maturing alternative and more efficient
means of propulsion while minimizing aircraft weight
[2]. This includes gearbox materials that improve over-
all life, alternative power transmission concepts that
increase power density, reductions in gearbox form
factor, as well as innovative lubrication methods that
reduce the amount of required lubricant or means of
cooling. One area of active research is in minimizing
gearbox windage for rotorcraft transmissions. Gear
windage power loss (WPL) reduces the efficiency of
the transmission due to drag on the gear teeth at high
surface speeds. Not only is windage drag detrimental
to gearbox efficiency, but the increased friction gener-
ates additional heating in the gearbox, thereby plac-
ing more demand on cooling requirements. Dudley
[3] highlights a number of points concerning WPL
for gearboxes: 1) windage losses become significant
above 10,000 fpm; 2) the use of ‘oil shields’ as shrouds
to reduce WPL; 3) the need to keep oil from building up
within the casing; 4) The use of ‘oil strippers’ to shield
discharge ports; 5) WPL decreases with increasing oil
inlet temperature; 6) additional losses occur due to oil
becoming trapped in the mesh.
Gearbox power losses can be divided into load-
dependent and load-independent losses. Load-
dependent losses are friction-related such as meshing
of the gear teeth or contact between bearing surfaces.
Sources of load-independent losses are those due to
bearings, seals, gear windage, gear churning, and
gear mesh pocketing losses [4]. This paper focuses on
shrouding for mitigating spur gear WPL in an air/oil
environment.
Experiments in air by Dawson [5] show a nearly
50% decrease in WPL, relative to the unshrouded
configuration, for a spur gear shrouded with a 0.59
in. (15 mm) radial clearance over a 270° sector and
a 1.06 in. (27 mm) axial clearance. Collaborative
work by Handschuh and Hurrell [6] and Hill [7] show
a decrease in WPL for a single shrouded spur gear
when compared to its unshrouded configuration.
Experimentally, Handschuh shows a ~30% decrease in
WPL at 25,000 ft./min. (127 m/s) for a 13 in. (330.2 mm)
pitch diameter spur gear with a 1.0 in. (25.4 mm) face
width in the shrouded 0.66 in. (16.7 mm) radial, 1.2 in.
(30.2 mm) axial clearance configuration. CFD work by
Hill [7] and others was able to show consistency with
the test data from that test configuration as well as
three additional configurations.
Lord [8] observed a ~80% decrease in WPL for a
shrouded 0.039 in. (1 mm) axial and radial clearance
7.9 in. (200 mm) pitch diameter, 1.6 in. (40 mm) face
width spur gear at 25,000 ft./min. (127 m/s), in air, and
compared it to test data in the unshrouded configu-
ration. However, he observed an order of magnitude
increase in WPL when testing the shrouded gear in
an ‘oil injection’ environment compared to the air-
only environment. Dawson [5] notes the potential for
this increase in WPL in discussing his series of spur
gear experiments in air. CFD analyses by Chaari et
August 2018     35
 Petry-Johnson et al. [13]. Pocketing losses as well as drag losses are modeled.

Table 1 – Comparison of selected spur gear WPL data from literature.

al. [9] on a single spur gear indicate an order
of magnitude increase in WPL at 20,000 rpm
(2,094 rad/s) with a corresponding increase in
pressure gradient between gear teeth due to
the change in environment from air to an air/
oil mixture. An effective density was used for
the analysis in an air/oil environment. Single
gear multiphase analyses by Kunz et al. [10]
also indicate a substantial increase in WPL
due to the air/oil environment. Handschuh
and Hurrell [6] observed a slight increase in
WPL for an unshrouded 13 in. (330 mm) pitch
diameter spur gear comparing data in an air
only environment to an air/oil environment.
This increase is notable above 30,000 ft./min.
(152 m/s). However, Handschuh reports that
the WPL is slightly greater for the maximumThe Table objective of this work
1: Comparison is to compare
of selected spur gearexperimental
WPL data fromwindage
literature.power loss data on meshed spur gears at
axial, maximum radial configuration in anintermediate shroud conditions with previous shrouded meshed spur gear experiments [11]. Experiments
are done at nearly
air/oil environment compared to an air only environment whileidentical
the oil flows and oil temperatures. Findings by the authors [14] as well as others
[3, 8] indicate that WPL is dependent, in part, on oil flow and temperature. Recommendations are given
opposite is observed for the remaining three configurations (i.e. min.
for future research.
radial/max. axial, min. radial/min. axial, max. radial/min. axial).
Experiments by Delgado and Hurrell [11] show Experimental
a 7x increase inApparatus
WPL
at 25,000 ft./min. (127 m/s) for unshrouded meshed spur gears when
Windage power loss data were collected in NASAʼs Gear Windage Power Loss Test Facility, Figure 1.
compared to the single unshrouded 13 in. (330 Themm) pitch
input shaftdiameter
of the test gearbox is connected to a 150 hp (112 kW) dc drive motor and 1:5.17 speed-
spur gear data from Handschuh and Hurrell [6].increasing
With 0.039 in. (1 mm)
gearbox. An opposing torsional load can be applied on the test gear output shaft using the
axial and radial shroud clearances, a 12x increase magnetic
in WPL particle brake rated to 890 in-lb (100 N-m) at 2900 rpm (304 rad/s). Friction clutches (carbon on
is observed
comparing single versus meshed spur gears. Table carbon friction wheels)
1 summarizes thelocated forward of the torquemeter and brake allow for disengagement of the test
gearbox input and output shafts. This enables the test hardware (i.e. shafts, bearings, test gears) to
WPL data presented from literature. A windage power loss analytical
coast-down from a preset pitch-line velocity. Current tests were limited to approximately 28,000 ft./min.
model on a spur gear pair by Seetharaman and(142 Kahraman
m/s). This[12]isshows
approximately 10,000 rpm (1047 rad/s) for an 11 in. (279 mm) pitch diameter pinion.
good agreement with experimental data on the same gears by Petry-
Tests can be run with and without shrouding. Aluminum plates are used for the axial shrouds while A366
Johnson et al. [13]. Pocketing losses as well as drag
lowlosses
carbon are modeled.]
sheet metal strips are used for radial shrouding, Figure 2. The shrouds are placed within a
The objective of this work is to compareclam-shell
experimentalhousing, wind-
Figure 3. The lower halves of both the drive- and driven-side clam-shell housing
age power loss data on meshed spur gears atcontain four oil drain
intermediate holes, each 0.75 in. (19 mm) wide by 3.5 in. (89 mm) long circumferentially. The
shroud
conditions with previous shrouded meshed spur shroud surface
gear roughness is approximately 63 µin. (1.6 µm). Six machined slots within the clam-shell
experiments
[11]. Experiments are done at nearly identicalhousing
oil flows allow
andforoilset clearances between the axial shroud wall and gear. The axial shroud walls, in turn,
tem-
have six machined slots to vary the radial shroud position, Figures 2 and 4. In order to facilitate assembly
peratures. Findings by the authors [14] as well as others [3, 8] indi-
of the rig, the clam-shell housing is composed of four pieces: 1) upper drive-side; 2) lower drive-side; 3)
cate that WPL is dependent, in part, on oil flow upperand temperature.
driven-side; 4) lower driven-side. The entire assembly is mounted within the test gearbox enclosing
Recommendations are given for future research. the test gears, Figure 3. An available clam-shell housing was tested as an intermediate shroud condition
to assess windage power loss with additional drain holes and grooves as shown in Figure 2 and Figure 3.
EXPERIMENTAL APPARATUS The gear fling-off temperature for Figure
Figure 1: 1 – Schematic
allSchematic
configurations of Gear
of Gearwas Windage
measured
Windage Power Power
at 30
Loss Loss Test
degrees
Test Facility.(0.52Facility.
rad.) clockwise,
Windage power loss data were collected in NASA’s relative to vertical
Gear on the drive-side pinion as viewed from the front of the test gearbox, Figure 1, with the
Windage
torquemeter
Power Loss Test Facility, Figure 1. The input shaft on gearbox
of the test the right side and the magnetic
position, Figures 2particle
and 4. brake on the
In order left side. Lubrication
to facilitate assembly ofwas
thedirected
rig,
into mesh, nominally at 0.9 gpm (4.1 lpm) at 120 psi (827 kPa). The lubricant used is a synthetic oil used
is connected to a 150 hp (112 kW) dc drive motor and 1:5.17 speed- the clam-shell housing is composed of four pieces:
specifically for gas turbine engines and helicopter transmissions and meets U.S. DoD-PRF-85734
1) upper drive-
increasing gearbox. An opposing torsional loadspecifications
can be applied on the
[15]. side; 2) lower drive-side; 3) upper driven-side; 4) lower driven-side.
test gear output shaft using the magnetic particle brake rated to 890 The entire assembly is mounted within the test gearbox enclosing
in-lb (100 N-m) at 2,900 rpm (304 rad/s). Friction clutches (carbon on the test gears, Figure 3. An available clam-shell housing was tested as
carbon friction wheels) located forward of the torquemeter and brake an intermediate shroud3condition to assess windage power loss with 17FTM04
allow for disengagement of the test gearbox input and output shafts. additional drain holes and grooves as shown in Figure 2 and Figure 3.
This enables the test hardware (i.e. shafts, bearings, test gears) to coast- The gear fling-off temperature for all configurations was measured
down from a preset pitch-line velocity. Current tests were limited to at 30 degrees (0.52 rad.) clockwise, relative to vertical on the drive-side
approximately 28,000 ft./min. (142 m/s). This is approximately 10,000 pinion as viewed from the front of the test gearbox, Figure 1, with the
rpm (1047 rad/s) for an 11 in. (279 mm) pitch diameter pinion. torquemeter on the right side and the magnetic particle brake on the
Tests can be run with and without shrouding. Aluminum plates left side. Lubrication was directed into mesh, nominally at 0.9 gpm
are used for the axial shrouds while A366 low carbon sheet metal (4.1 lpm) at 120 psi (827 kPa). The lubricant used is a synthetic oil used
strips are used for radial shrouding, Figure 2. The shrouds are placed specifically for gas turbine engines and helicopter transmissions and
within a clam-shell housing, Figure 3. The lower halves of both the meets U.S. DoD-PRF-85734 specifications [15].
drive and driven-side clam-shell housing contain four oil drain holes, Figure 2 – Configuration of radial and axial shrouding. Axial shrouds are 0.25 in. (6.35 mm) thick.
each 0.75 in. (19 mm) wide by 3.5 in. (89 mm) long circumferentially. EXPERIMENTATION
The shroud surface roughness is approximately 63 μin. (1.6 μm). Six The spur pinion and gear specifications are given in Table 2.
machined slots within the clam-shell housing allow for set clear- Meshed spur gear tests were run in unshrouded and shrouded
ances between the axial shroud wall and gear. The axial shroud configurations at an oil inlet temperature of approximately
walls, in turn, have six machined slots to vary the radial shroud 100°F (38°C). The oil inlet temperature was measured at a
4 17FTM04
36     gearsolutions.com
 shrouded configurations. Figure 5 shows
the 0.039 in. (1 mm) axial and radial shroud-
ing configuration with drain slots on both
the drive and driven side prior to assembly.
For all shroud configurations, drain slots
were approximately 3.5 in. (89 mm) long
circumferentially by (0.75 in.) 19 mm wide.
All tests were run with a 10 in-lb (1.1
N-m) counter-torque to prevent gear tooth
disengagement during rotation. The meshed
spur gears were rotated to 10,000 rpm
in 2,000 rpm increments. The speed was
changed every 100 seconds with approxi-
mately 20 seconds used to transition to the
next speed increment and 80 seconds to
hold at speed. After holding at the 10,000
rpm-condition, the drive motor and dyna-
mometer are simultaneously disengaged,
allowing the test gears, input shaft, and
Figure 2: Configuration of radial and axial shrouding. Axial shrouds are 0.25 in.
gure 2 – Configuration of radial and axial shrouding. Axial shrouds are 0.25 in. (6.35 mm) (6.35 mm) thick. thick.
output shaft to coast-down. This process
was repeated for a total of three cycles. An
example ramp-up and wind-down cycle is
shown in Figure 6. Data was recorded at
3 Hz capture rate.
Test data was taken for the U, C6, C31,
and C36 configurations while data from [11]
was used for the C1 and CS configuration.
4 17FTM04
Third cycle data is compared for all six con-
figurations.

GEAR WINDAGE POWER LOSS

Figure 3: TestFigure 3 – Test
gearbox showing gearbox
clam-shell showing
(CS) enclosure clam-shell
for shrouding within (CS) enclosure
the NASA gearbox.
for shrouding within the NASA Gearbox.
point in the stainless steel oil inlet supply approximately 5 ft.
(1.5 m) prior to entering the test gearbox. Two unshrouded configura-
tions were tested: unshrouded with no clam-shell housing installed,
designated U, and unshrouded with the clam-shell housing installed,
designated CS. The U configuration is simply the two meshed spur
gears installed in the gearbox. Both the gear mesh lube flow and bear-
ing lube flow were held constant at nominally 0.9 gpm (4.1 lpm) and
0.2 gpm (0.9 lpm), respectively. Gear mesh lubrication was into mesh
for all configurations using two 0.125 in. (3.2 mm) o.d. stainless steel
tubes with 0.02 in. (0.5 mm) wall thickness. The CS configuration
is the U configuration with the clam-shell housing installed. Four
shroud configurations were tested. Designations for the shrouded
configurations are C36 (max. axial, max. radial, C1 (min. axial,
min. radial), C31 (max. axial, min. radial), and C6 (min. axial, max.
radial). Table 3 provides the clearances for the unshrouded and
CALCULATION
The total power loss consists of gear mesh
losses, rig driveline losses, and windage loss-
es. Considering the light loading of the gear
set during the tests reported herein, the gear
mesh losses are minimal. Gear mesh losses
are conservatively calculated to be 0.14 hp
(0.1 kW) average at 10 in-lb. (1.1 N-m) torque
over the meshing cycle, based on analyses by
Anderson and Loewenthal [16]. Alternative
meshing loss calculations due to sliding and
rolling were found to be negligible [17]. The
rig driveline losses, or tare losses, consist of
power losses associated with the spinning
drive shaft, driven shaft, and support bear-
ings. These losses were determined by per-
forming coast-down tests without the test gears installed. The tare
windage power loss for the drive shaft and bearing assembly was
experimentally determined at each test temperature. The driven
shaft and bearing assembly tare windage power loss were assumed
to be the same since both shafts are nearly identical, with the excep-
tion of the gear spline diametral pitch.
Similar to Dawson [5], power loss due to windage was calculated,
in part, by plotting the angular velocity versus time curve during
free deceleration and measuring the slope or instantaneous angu-
lar acceleration at various points on that curve. Torque is given by
the product of the angular acceleration and the moment of inertia.
An equivalent moment of inertia, Jeq, for the meshed gear system is
given by Equation 1 [18]. The power (or windage power loss) of the
meshed gear system is calculated from the product of the torque and
the shaft speed. Finally, the windage power loss due the gears alone
August 2018     37
ower loss due to windage was calculated, in part, by plotting the angular velocity
g free deceleration and measuring the slope or instantaneous angular
points on that curve. Torque is given by the product of the angular acceleration
a. An equivalent moment of inertia, J eq , for the meshed gear system is given by
e power is
(orgiven
windage power loss) of
by subtracting thetare
the meshed
power gear system is calculated from
losses
e and the shaft speed. Finally, the windage power loss due the gears alone is
and gear mesh losses from the power
tare power losses and gear mesh losses from the powerloss of loss of the meshed gear
the meshed gear system.
2 Experimentation
N 
J eq= J1 + J 2  1  Equation 1 The spur pinion and gear specifications are given in Table 2. Meshed spur gear tests were run in
 N2  unshrouded and shrouded configurations at an oil inlet temperature of approximately 100°F (38°C). The
oil inlet temperature was measured at a point in the stainless steel oil inlet supply approximately 5 ft.
(1.5 m) prior to entering the test gearbox. Two unshrouded configurations were tested: unshrouded with
where J 1 = moment of inertia of the pinion no clam-shell housing installed, designated U, and unshrouded with the clam-shell housing installed,
designated CS. The U configuration is simply the two meshed spur gears installed in the gearbox. Both
e measured using the J2 =curved
momentrail method
of inertiaoutlined by Genta and Delprete
of the gear the gear[18].
mesh lube flow and bearing lube flow were held constant at nominally 0.9 gpm (4.1 lpm) and
erimental setup for the curved rail procedure. The test shaft assemblies, 0.2 gpm drive
(0.9and
lpm), respectively. Gear mesh lubrication was into mesh for all configurations using two
with and without the N 1test
= number of pinion
gears. The inertiasteeth
measured using the test shaft
0.125 in. (3.2 mm) o.d. stainless steel tubes with 0.02 in. (0.5 mm) wall thickness. The CS configuration is
est gears are used in calculating the rig driveline losses. The inertia, the J,
U given by
configuration with the clam-shell housing installed. Four shroud configurations were tested.
d using the test shaftN 2assemblies
= number of gear
with the teeth
test gears and are usedDesignations
in determining for the shrouded configurations are C36 (max. axial, max. radial, C1 (min. axial, min. radial),
. C31 (max. axial, min. radial), and C6 (min. axial, max. radial). Table 3 provides the clearances for the
2
unshrouded and shrouded configurations. Figure 5 shows the 0.039 in. (1 mm) axial and radial shrouding
 gT 
J = mr 2  − 1 Equation 2 configuration with drain slots on both the drive and driven side prior to assembly. For all shroud
 4π ( R − r ) 8  configurations, drain slots were approximately 3.5 in. (89 mm) long circumferentially by (0.75 in.) 19 mm
17FTM04
wide.
All tests were run with a 10 in-lb (1.1 N-m) counter-torque to prevent gear tooth disengagement during
where J = moment of inertia of the assembly rotation. The meshed spur gears were rotated to 10,000 rpm in 2000 rpm increments. The speed was
changed every 100 seconds with approximately 20 seconds used to transition to the next speed
= total mass of the assembly increment and 80 seconds to hold at speed. After holding at the 10,000 rpm-condition, the drive motor
= radius of shaft bearing journal and dynamometer are simultaneously disengaged allowing the test gears, input shaft, and output shaft to
coast-down. This process was repeated for a total of three cycles. An example ramp-up and wind-down
= radius of curved rail of test apparatus cycle is shown in Figure 6. Data was recorded at 3 Hz, capture rate.
= period of oscillation of assembly Test data was taken for the U, C6, C31, and C36 configurations while data from [11] was used for the C1
= gravitational constant and CS configuration. Third cycle data is compared for all six configurations.
Figure 4 – Configuration
Figure 4: Configuration of axial
of axial and radial andusing
shrouding radial shrouding
machined slots. Axialusing
shrouds machined slots.
are 0.25 in. (6.35 mm)
thick. Axial shrouds are 0.25 in. (6.35 mm) thick.
Component inertias were measured Table 2 – Pinion (drive-side) and gear (driven-side) specifications.
using the curved rail method outlined by
Gear Parameter Drive-side Driven-side
Genta and Delprete [18]. Figure 7 shows the
experimental setup for the curved rail pro- number of teeth 44 52
cedure. The test shaft assemblies, drive and 5 17FTM
driven, were assembled with and without pitch/mod., 1/in. (mm) 4 (6.35)

the test gears. The inertias measured using face width, in. (mm) 1.12 (28.4) 1.12 (28.4)
the test shaft assemblies without the test
gears are used in calculating the rig drive- pitch dia., in. (mm) 11.0 (279.4) 13.0 (330.2)
line losses. The inertia, J, given by Equation 2
pressure angle, deg (rad) 25 (0.44)
are measured using the test shaft assemblies
with the test gears and are used in determin- outside dia., in. (mm) 11.49 (291.9) 13.49 (342.7)
ing the gear windage losses.
Material Steel-SAE 5150H

DISCUSSION AND FUTURE WORK surface finish, µin (µm) 16 (0.4)

Figure 8 shows example WPL data for a
e experimental setup for tare loss calculation using curved rail method.
shrouded configuration for three consecu- Table 2: Pinion (drive-side) and gear (driven-side) specifications.
Table 3 – Nominal shroud configuration clearances.
tive wind-down cycles. The WPL values
Future Work
decrease slightly with each successive wind- Axial Clearance Radial Clearance
e WPL data downfor acycle.
shrouded
Thisconfiguration for three consecutive
is due to increasing air/oil wind-down cycles.
se slightly with each successive wind-down cycle. This is due to increasing air/oil Shroud Configuration
temperatures within the gearbox, caused by Per side Drive-side Driven-side
gearbox, caused by the rotating meshed spur gears. Experience with the test rig in. (mm) in. (mm) in. (mm)
theshown
urations has rotating
that meshed
with eachspur gears.cycle,
successive Experience
the difference in WPL
ing cyclewith
is progressively
the test rigless.
overAlthough it is
several likely
test that WPL values(U)
configura- wouldunshrouded 2.25 (57) 2.5 (64) 1.0 (25)
creasing cycles, a three-cycle test procedure was used to maintain data
tions has shown that with each successive
ciency.
cycle, the difference in WPL compared to (CS) unshrouded with clam-shell housing 1.5 6 (38) 0.82 (21) 0.82 (21)
17FTM04
values of oil inlet temperature, oil exit temperature, gear oil flow and bearing oil
the preceding cycle is progressively less.
rouded/unshrouded configurations. Approximately 100 data points(C1) were shrouded 0.039 (1) 0.039 (1) 0.039 (1)
. Recall from Figure it
Although 6 that approximately
is likely that WPL 30 values
to 40 seconds
wouldof data at 3 Hz are
from 10,000 rpm. Average
decrease furtheroilwith
inlet temperatures
increasing ranged
cycles,from
a 101°F(C6)(38°C) to
shrouded 0.039 (1) 0.66 (17) 0.66 (17)
three-cycle test procedure was used to main-
(C31) shrouded 1.17 (30) 0.039 (1) 0.039 (1)
tain data consistency and test efficiency.
Table 4 shows9average values of oil inlet 17FTM04
(C36) shrouded 1.17 (30) 0.66 (17) 0.66 (17)
temperature, oil exit temperature, gear oil
flow, and bearing oil flow for the six test- Table 3: Nominal shroud configuration clearances.
ed shrouded/unshrouded configurations.
Approximately 100 data points were averaged for each value. Recall peratures ranged from 101°F (38°C) to 109°F (43°C). Average oil exit
from Figure 6 that approximately 30 to 40 seconds of data at 3 Hz temperatures varied from 137°F (58°C) to 163°F (73°C). The oil exit tem-
are used during coast-down from 10,000 rpm. Average oil inlet tem- peratures for the shrouded configurations (C1, C6, C31, and C36) were
38     gearsolutions.com
 and flow rate. Thus, an effort was made to control, to the extent possible, both parameters for these
sets.

rtias were measured using the curved rail method outlined by Genta and Delprete [18].
the experimental setup for the curved rail procedure. The test shaft assemblies, drive and
sembled with and without the test gears. The inertias measured using the test shaft
hout the test gears are used in calculating the rig driveline losses. The inertia, J, given by
measured using the test shaft assemblies with the test gears and are used in determining
ge losses.

 gT 2 
J = mr 2  − 1 Equation 2
 4π ( R − r ) 
Figureconfiguration
Figure 5: C1 shroud 5 – C1 shroud configuration
with drain slots. with drain slots.

Figure
Figure 8 – Example
8: Example WPL
WPL data setdata set three
showing showing three cycles.
wind-down wind-down cycles.
where J = moment of inertia of the assembly
= total mass of the assembly configurations give the
Table 4 – Average highest
ʻCycle WPL values
3 wind-downʼ observed, followed
oil temperatures and flowsby the
for various shroud
C6, C36, and C1 configurations. configurations.
At 25,000 ft./min. (127 m/s) the reduc-
= radius of shaft bearing journal tion in WPL is 10% between the oil unshrouded
inlet oil(U,
exitCS) and shrouded
gear inlet bearing
(C6, C36,
Shroud and C1) configurations.temp.
Configuration There was little temp.
difference oil-flow
observed oil-flo
= radius of curved rail of test apparatus in WPL between the C6, C36, and C1 configurations. Previous gpm (lpm) single gpm (l
°F (°C) °F (°C)
= period of oscillation of assembly spur
(U) unshrouded
gear studies in both air only
107
[5-8,
(41)
10] and
163
air/oil
(73)
[6] have shown
0.91 (4.1) 0.27 (
measurable differences in WPL with the minimum axial/radial clear-
= gravitational constant (CS) unshrouded with clam-shell housing 102 (39)
ances generally having the greatest reduction in WPL.162 (72) 0.90 (4.1) 0.14 (

7 (C1) shrouded The largest reduction 109

17FTM04 (29%)(43) in WPL 143 were(62) observed
0.91 (4.1)for 0.18 (

(C6) shrouded
the C31 configuration (max.
107
axial,
(41)
min.151
radial).
(66)
This experi- 0.19 (
0.91 (4.1)
ment was repeated to check consistency of the results, Figure
(C31) shrouded
10. Recall that previous shrouded 101 (38)single137gear (58) 1.07 (4.9)by 0.18 (
experiments
(C36) shrouded 101 (38) 144 (62) 0.85 (3.9) 0.19 (
Figure 6: Example windage test ramp-up and wind-down cycle.
WPL measurements are shown in Figure 9 for the configurations given in Table 3. Below 15,000 ft./m
(76 m/s), WPL values are essentially identical, regardless of shroud configuration or lack thereof. Th
Figure 6 – Example windage test ramp-up and wind-down cycle.
in line with findings by other researchers that WPL is relatively insignificant below approximately 10,0
ft./min. (51 m/s) [19, 20]. Above 10,000 ft./min. (51 m/s), the unshrouded and CS configurations give
Gear Windage Power Loss Calculation highest WPL values observed, followed by the C6, C36, and C1 configurations. At 25,000 ft./min. (12
The total power loss consists of gear mesh losses, rig driveline losses, and windagem/s) the Considering
losses. reduction in WPL is 10% between the unshrouded (U, CS) and shrouded (C6, C36, and C1)
the light loading of the gear set during the tests reported herein, the gear mesh lossesconfigurations.
are minimal. There
Gear was little difference observed in WPL between the C6, C36, and C1 configurat
mesh losses are conservatively calculated to be 0.14 hp (0.1 kW) average at 10 in-lb. Previous single
(1.1 N-m) spur gear studies in both air only [5-8, 10] and air/oil [6] have shown measurable
torque
over the meshing cycle, based on analyses by Anderson and Loewenthal [16]. Alternative meshing loss
calculations due to sliding and rolling were found to be negligible [17]. The rig driveline losses, or tare
losses, consist of power losses associated with the spinning drive shaft, driven shaft, and support
bearings. These losses were determined by performing coast-down tests without the test gears installed. 10 17F
The tare windage power loss for the drive shaft and bearing assembly was experimentally determined at
each test temperature. The driven shaft and bearing assembly tare windage power loss were assumed to
be the same since both shafts are nearly identical, with the exception of the gear spline diametral pitch.
Similar to Dawson [5], power loss due to windage was calculated, in part, by plotting the angular velocity
versus time curve during free deceleration and measuring the slope or instantaneous angular
acceleration at various points on that curve. Torque is given by the product of the angular acceleration
and the moment of inertia. An equivalent moment of inertia, J eq , for the meshed gear system is given by
Equation 1 [Ref. 18]. The power (or windage power loss) of the meshed gear system is calculated from
Figure
the product of 7: Example
the torque experimental
and the setup
shaft speed. for tare
Finally, the loss calculation
windage usingdue
power loss curved rail alone is
the gears
method. the tare power losses and gear mesh losses from the power loss of the meshed gear
given by subtracting
Example experimental setup for tare loss calculation using curved rail
system.
method.
noticeably lower, 10°F to 20°F (~6°C to 11°C), than the unshrouded
2
 Ninlet

configurations (U and CS). Gear
J eq= J1 + J 2  1 
oil Equation
flow rates 1
ranged from 0.85
GLEASON-PFAUTER
n and Future Work
gpm (3.86 lpm) to 1.07 gpm (4.86  N 2 lpm) while bearing inlet oil flow
P1200/1600ES
rates varied from 0.14 gpm (0.64 lpm) to 0.27 gpm (1.23 lpm). Research
examplehas WPL data
shown thefor a shrouded
variation
where in J 1 WPL
configuration
withofboth
= moment inertiaoil
for three consecutive
of temperature
the pinion and flow wind-down cycles.
CNC Gear Shaper, with SIEMENS
s decreaserate.slightly
Thus, anwith each
effort successive
was made to control, wind-down
to the extent cycle. Thisboth
possible, is due to increasing
840D, 1600mmair/oil
max diameter, 820 Cochran Street
J 2 = moment of inertia of the gear Statesville, NC 28677
ithin the parameters
gearbox, caused by the
for these data sets. rotating meshed spur gears. Experience with the test rig
2000mm swing, 400 mm stroke 704.609.0766
st configurations has shown that
WPL measurements N 1 =with
are number
shown eachof successive
inpinion
Figureteeth9 for thecycle, the difference
configura- in WPLinstalled 2011, with
positioning, www.pisellient.com
e precedingtionscycle
givenisinprogressively less.
15,000Although
N 2 = number
Table 3. Below offt./min.
gear teeth(76it ism/s),
likely
WPL that WPL values
values would
SPECIAL SHUTTLE STROKE OPTION! rich@pisellient.com
r with increasing cycles,
are essentially a three-cycle
identical, regardlesstest procedure
of shroud was used
configuration to maintain data
or lack
d test efficiency.
thereof. This is in line with findings by other researchers that WPL THE #1 SOURCE FOR YOUR USED MEMBER
is relatively insignificant below approximately
average m/s)
values of oil inlet temperature, 8
oil exit
10,000 ft./min. (51 17FTM04
temperature, gear oil flowGEAR
and MACHINERY
bearing oil — AND MORE!
[19, 20]. Above 10,000 ft./min. (51 m/s), the unshrouded and CS
ested shrouded/unshrouded configurations. Approximately 100 data points were
ach value. Recall from Figure 6 that approximately 30 to 40 seconds of data at 3 Hz are August 2018     39
ast-down from 10,000 rpm. Average oil inlet temperatures ranged from 101°F (38°C) to
 Figure 8 – Example WPL data set showing three wind-down cycles.

Table 4 – Average ʻCycle 3 wind-downʼ oil temperatures and flows

for various shroud configurations.
a slight increase in WPL.
oil inlet oil exit gear inlet bearing inlet
Shroud Configuration temp. temp. oil-flow oil-flow The substantial improvement in WPL
°F (°C) °F (°C) gpm (lpm) gpm (lpm) reduction for the maximum axial, minimum
radial shroud condition shows a need for fur-
(U) unshrouded 107 (41) 163 (73) 0.91 (4.1) 0.27 (1.2)
ences in WPL with the minimum axial/radial clearances generally having the greatest reduction in ther research. Earlier work by the authors [11]
(CS) unshrouded with clam-shell housing 102 (39) 162 (72) 0.90 (4.1) 0.14 (0.6) indicated a more than doubling of the WPL
(C1) shrouded
argest reduction (29%) in WPL were observed for the C31 109 (43)
configuration 143
(max. (62) 0.91
axial, min. (4.1)
radial). 0.18 (0.8) when comparing data between single and
xperiment was repeated to check consistency of the results, Figure 10. Recall that previous meshed spur gears. For the unshrouded case,
ded single(C6)
gear shrouded
experiments by Handschuh [6] show that107 (41) reductions
the largest 151 (66)
in WPL0.91
occur (4.1)
at 0.19 (0.9)
this difference was approximately 7x. For the
nimum axial
(C31)andshrouded
minimum radial shroud clearance configuration,
101 (38)followed
137 by the
(58)minimum
1.07 (4.9) 0.18 (0.8)
maximum radial clearance shroud configuration and the maximum axial/minimum radial shroud shrouded case, an even greater increase of
nce configuration. Data by Lord [8] for a single gear show
(C36) shrouded 101a decrease
(38) in WPL (62)
144 with increased
0.85 (3.9)radial 0.19 (0.9) 12x was observed. Two promising areas for
d clearance 0.039 in. to 0.200 in. (1 to 5 mm) while holding the axial clearance at 0.039 in. (1 mm) further research include pocketing losses
WPL
onstant oil
Table measurements
flow4:
rate. “cycleare
However,
Average shown
holding theinradial
3 wind-down” Figure 9 for the configurations
clearance
oil temperatures at and
0.039 (1 given
in. for
flows mm) in shroud
Table
while
various 3.configurations.
Below
changing the15,000 ft./min.
(76 m/s), WPL values are essentially identical, regardless of shroud configuration
clearance from 0.039 in. to 0.200 in. (1 to 5 mm) at constant oil flow rate resulted in a slight increase or lack thereof. This is [12] and high velocity axial fluid flow at the
L. in line with findings by other researchers that WPL is relatively insignificant below approximately 10,000 meshing region [21].
ft./min. (51 m/s) [19, 20]. Above 10,000 ft./min. (51 m/s), the unshrouded and CS configurations give the
Further, although the results are specifically for spur gears, in
highest WPL values observed, followed by the C6, C36, and C1 configurations. At 25,000 ft./min. (127
m/s) the reduction in WPL is 10% between the unshrouded (U, CS) and shrouded (C6, principle,
C36, andthere
C1) is potential to improve WPL for differing types of
configurations. There was little difference observed in WPL between the C6, C36, and gearC1 meshes
configurations.
(i.e. helical, spiral bevel, face) for helicopter gearboxes
Previous single spur gear studies in both air only [5-8, 10] and air/oil [6] have shown measurable
particularly above 15,000 ft./min. For example, the V-22 transmission
contains helical gear meshes rotating in excess of 20,000 ft./min.
[22]. The OH-58 contains a two-stage helical gear reduction from the
10 17FTM04
turboshaft engine, reducing the output shaft speed from 35,000 rpm
to 6,000 rpm at the input to the main gearbox. Also, the UH-60 main
rotor transmission contains a spiral bevel gear reduction at an input
shaft speed of 21,000 rpm [23].
Future work is needed to determine the effect on
W PL of out- of-mesh lubrication, oil jet size and f low,
as well as oil drain hole geometry and location. These param-
eters were held constant for the results given above. Out-of-mesh
lubrication experiments would address gear cooling needs in rela-
tion to WPL improvements using shrouds. Previous work by the
authors [14] with the same experimental setup have demonstrated
ure 9 – Comparison of meshed
Figure 9: Comparison spur gear
of meshed windage
spur gear power
windage powerloss
lossversus
versus shroud
shroud configuration.
increased WPL with in-to-mesh lubricant flow. Those same set of
configuration. experiments have also demonstrated decreased WPL with increased
lubricant temperature. Thus, adjusting oil jet size as well as oil flow
at required temperatures for adequate gear lubrication and cool-
ing would need to be weighed against WPL improvements. Finally,
optimizing oil drain hole geometry and location is necessary to
quickly remove the lubricant from the vicinity of gear rotation and
meshing to minimize the amount of oil to be recirculated into the
system thereby increasing WPL. Results from these efforts would
increase understanding of WPL and its potential effects on the effi-
ciency of not only a single spur gear pair but, by extension, general
effects on a gearbox. 

REFERENCES
[ 1 ] Weden, Gilbert J., and John J. Coy. “Summary of drive-train component
technology in helicopters.” (1984).
[ 2 ] http://www.hq.nasa.gov/office/aero/pdf/armd-strategic-implementation-
plan.pdf
[ 3 ] Dudley, D.W., 1962, Gear handbook: the design, manufacture, and applica-
Figure
Figure10
10:–Repeat
Repeat WPL
WPL datadata for C31
for C31 configuration
configuration (max. axial/min.
(max. axial/min. radial). radial).
11 tion of gears, McGraw Hill Book Company, New York, Chap. 14.
17FTM04

ubstantialHandschuh
improvement[6] in WPL
showreduction
that thefor largest
the maximum axial, minimum
reductions in WPLradial
occurshroud [ 4 ] Michaelis, K., and Höhn, B-R., 1994, “Influence of Lubricants on Power
at condition
s a need the
for further research. Earlier work by the authors [11] indicated
minimum axial and minimum radial shroud clearance configu- a more than doubling Loss of Cylindrical Gears,” Tribology Transactions, 37(1), pp.161–167.
of the
when comparing data between single and meshed spur gears. For the unshrouded case, this
ence wasration, followed7x. by
Forthe
the minimum axial/maximum
an even greater radial
increaseclearance
[ 5 ] Dawson, P. H., 1984, “Windage loss in larger high-speed gears,”
approximately shrouded case, of 12x was observed.
romisingshroud
areas forconfiguration
further research and the
include maximum
pocketing lossesaxial/minimum radial
[12] and high velocity axial fluid flow Proceedings
at of the Institution of Mechanical Engineers, Part A: Power and
eshing region
shroud [21].clearance configuration. Data by Lord [8] for a single gear Process Engineering, 198(1), pp.51–59.
er, although
show thearesults are specifically
decrease in WPL with for increased
spur gears, radial
in principle,
shroudthere is potential
clearance to improve
0.039 [ 6 ] WPL
Handschuh, R. F., and Hurrell, M. J., 2010, “Initial Experiments of High-
fering types of gear
in. to 0.200meshes (i.e.
in. (1 to helical,while
5 mm) spiralholding
bevel, face)
thefor helicopter
axial gearboxes
clearance particularly Speed Drive System Windage Losses,” International Conference on Gears,
at 0.039
15,000 ft./min. For example, the V-22 transmission contains helical gear meshes rotating in excess Munich, Germany.
in. [22].
000 ft./min. (1 mm) at a constant
The OH-58 contains a oiltwo-stage
flow rate. However,
helical holding
gear reduction the
from theradial
turboshaft engine,
ng the output shaft speed
clearance from
at 0.039 in.35,000
(1 mm)rpm to 6000
while rpm at the
changing theinput
axialtoclearance
the main gearbox.
from Also, [ 7 ] the
Hill, M.J., 2010, “A Computational Investigation of Gear Windage,” Ph.D.
0 main rotor
0.039transmission contains
in. to 0.200 in. (1 atospiral
5 mm) bevel
at gear reduction
constant at an rate
oil flow inputresulted
shaft speedin of 21,000thesis, The Pennsylvania State University.
23].
e work is40      gearsolutions.com
needed to determine the effect on WPL of out-of-mesh lubrication, oil jet size and flow,
ll as oil drain hole geometry and location. These parameters were held constant for the results
above. Out-of-mesh lubrication experiments would address gear cooling needs in relation to WPL
[ 8 ] Lord, A. A., 1998, “Experimental investigation of geometric and oil flow
effects on gear windage and meshing losses,” Ph.D. thesis, University of
Wales Swansea.
[ 9 ] Chaari, F., Romdhane, M.B., Baccar, W., Fakhfakh, T., and Haddar, M.,
2012, “Windage power loss in spur gear sets,” Wseas transactions on
applied and theoretical mechanics, 7(2), pp.159–168.
[ 10 ] Kunz, R. F., Hill, M. J., Schmehl, K. J., McIntyre, S. M., 2012, “Computational
Study of the Roles of Shrouds and Multiphase Flow in High Speed Gear
Windage Loss,” AHS International 68th Annual Forum and Technology
Display, Ft. Worth, Texas.
[ 11 ] Delgado, I., and Hurrell, M., 2017, “Experimental Investigation of Shrouding
on Meshed Spur Gear Windage Power Loss,” AHS International 73rd Annual
Forum and Technology Display, Ft. Worth, Texas.
[ 12 ] Seetharaman, S., Kahraman, A., 2010, “A windage power loss model for
spur gear pairs,” Tribology Transactions, 53(4), pp.473–484.
[ 13 ] Petry-Johnson, T.T.,Kahraman, A., Anderson, N.E., and Chase, D.R.,
2008, “An experimental investigation of spur gear efficiency,” Journal of
Mechanical Design, 130(6), pp.062601-1 to -10.
[ 14 ] Delgado, I, and Hurrell, M., 2017, “Baseline Experimental Results on the
Effect of Oil Temperature on Shrouded Meshed Spur Gear Windage Power
Loss,” Proceedings of the ASME 2017 International Design Engineering
Technical Conferences & Computers and Information in Engineering
Conference, Cleveland, Ohio.
[ 15 ] Anderol Specialty Lubricants, “Anderol Product Data Sheet – Royco 555,”
DoD-PRF-85734, from < http://qclubricants.com/msds/PDS/Royco555.pdf>.
[ 16 ] Anderson, N. E., and Loewenthal, S. H., 1981, “Effect of geometry and
operating conditions on spur gear system power loss,” Journal of Mechanical
Design, 103(1), pp.151–159.
[ 17 ] Windows LDP 4.8.0. Computer Program, GearLab, The Ohio State
University, 2017.
[ 18 ] G e n t a ,
G . , a n d D e l p r e t e , C . , 19 9 4 , “ S o m e c o n s i d -
erations on the experimental determination of mo -
ments of inertia.” Meccanica, 29(2), pp.125–141.
[ 19 ] Dudley, D. W., 1991, Dudley’s Gear Handbook. Ed. Dennis P. Townsend.
Tata McGraw-Hill Education, Chap. 12.
[ 20 ] Diab Y.Y., Ville F.F., Velex P.P., Changenet C.C., 2004, “Windage Losses in
High Speed Gears— Preliminary Experimental and Theoretical Results,”
Journal of Mechanical Design, 126(5), pp. 903– 908.
[ 21 ] Pechersky, M. J., Wittbrodt, M.J., 1989, “An analysis of fluid flow between
meshing spur gear teeth.” 1989 International Power Transmission and
Gearing Conference, 5th, Chicago, IL.
[ 22 ] Kilmain, C. J., Murray, R., Huffman, C., 1995, “V-22 Drive System
Description and Design Technologies,” AHS International 51st Annual
Forum and Technology Display, Ft. Worth, Texas.
[ 23 ] Weden, G. J., Coy, J. J., 1984, “Summary of Drive-Train Component
Technology in Helicopters,” NATO-AGARD PEP 64th Symposium on Gears
and Power Transmissions for Helicopters and Turboprops, Lisbon, Portugal.

ABOUT THE AUTHORS

I.R. Delgado is with NASA, and M.J. Hurrell is with HX5 Sierra LLC. Learn more at www.nasa.gov and www.tfome.com. The authors acknowledge
the support of the NASA Revolutionary Vertical Lift Technology Project and also to Sigurds Lauge (HX5 Sierra LLC) for technical test support.
Copyright© 2017, American Gear Manufacturers Association, ISBN: 978-1-55589-547-1, 17FTM04. The statements and opinions contained
herein are those of the authors and should not be construed as an official action or opinion of the AGMA. Go to www.agma.org.

August 2018     41
 AREAL
EVALUATION
OF INVOLUTE
GEAR FLANKS
WITH 3D
SURFACE DATA

Printed with permission of the copyright holder, the American Gear Manufacturers Association, 1001 N. Fairfax Street, Suite 500, Alexandria,
Virginia 22314. Statements presented in this paper are those of the authors and may not represent the position or opinion of the American Gear
Manufacturers Association. (AGMA) This paper was presented October 2017 at the AGMA Fall Technical Meeting in Columbus, Ohio. 17FTM08

42     gearsolutions.com
 University of North Carolina at Charlotte
Kang Ni
University of North Carolina at Charlotte
How examinations of involute gear flanks Dr.using areal,
Gert Goch

three-dimensional surface data provide in-depth,

University of North Carolina at Charlotte

holistic information
1 about the gears.
Introduction

By YUE PENG, KANG NI,Gears areGERT

and DR. decisive
GOCHcomponents in transmission systems. The quality of the gears de
performance of the transmission system they construct, including the power transmis

W
transmission accuracy, noise and vibration, reliability, and life time. The geometry of
ith the evolution of size, by
controlled weight, surface
quality technology
inspection processesas well as the mechanical
to ensure alignments
their conformance and
with the desig
structure, and tolerance requirements the motion control needed to ensure the correct path
Until today, tactile measurements followed by a line-oriented evaluation procedure h
in gear production and application, gear of probing, the measurement speed of tactile systems
dominant method to assess the deviations of gears from their nominal geometry.
metrology is challenged at the same time is limited. Therefore, only two lines on both flank sur-
to fulfill the cycle time requirements and to support faces of four teeth are measured for flank geometry
During a tactile measurement, the probe physically approaches and contacts the pre
the varieties in gear dimensions and geometry. The inspection, as a convention in industry (at least three
points or scans along the prescribed lines in the profile and helix direction. Due to th
standard gear flank inspection is based on measuring teeth required in ISO 1328-1 [1]). The relative positions
technology as well as the mechanical alignments and the motion control needed to e
two-dimensional line features (classically one profile of the flanks are measured by a single point on each
path of probing,
and one helix per tooth) on selected the measurement
gear teeth (usu- flank,speed captured of tactile systems
at the pitch is limited. diameter.
measurement Therefore, only
flank surfaces of four
ally four teeth selected), and graphically evaluating teeth are measured for flank geometry inspection,
It takes about three minutes to inspect an automotive as a conven
least three teeth required
the lines for deviation parameters. When inspecting in ISO 1328-1 [1]). The relative positions
cylindrical gear following this standard procedure, of the flanks are m
point on each flank,
structured modifications on gear flanks, multiple captured at the pitch measurement diameter.
while the same set of measurement tasks could take It takes about thre
an automotive cylindrical
lines are sampled to examine the whole surface, which gearup to an hour on a large gear, used, for example,same
following this standard procedure, while the in set
significantly increases thetasks could take
measurement time.upOptical
to an houranon a large
energy gear, used, for example, in an energy syste
system.
methods start to gain attention for gear measurement
with the benefits of fast sampling and high data den-
sity. However, the evaluations are still carried out by
extracting and evaluating a limited number of lines
from the large data cloud. This paper focuses on the
evaluation of involute gear flanks with areal, three-
dimensional surface data, providing holistic informa-
tion of the gears. The three-dimensional gear model
and the plumb line distance model enable the calcula-
tion of deviations in the surface normal direction of a
gear flank. This paper presents the benefits of an area-
oriented inspection of gear flanks, comprising math-
ematical approaches for areal descriptions of involute
surfaces, deviations, and modifications, as well as the
characterization of areal data with “3D gear deviation
parameters.” Approximation and orthogonal Figure 1 – Tactile
polyno- Figuremeasurements
1: Tactile measurements of of
a agear
gear onononeone
of the ofselected
the selected
mial decomposition methods are applied for surface (one profile,
flanks (oneone helix
profile, line,
one helix and
line, and a pitch
a pitch point
point illustrated)
illustrated)
reconstruction and parameter calculation. Measured
gear data is analyzed and Modern transmission
comparisons systems impose
with conven- Modernincreasing
transmission requirements
systems impose on the performance o
increasing
tional evaluation results tighter tolerances on the flank geometry and more complex modifications lead-
are presented. requirements on the performance of gears, of the flank
example, sinusoidally shapeding to tighter tolerances
modifications have been on the flank geometry
investigated to reduceand the no
1: INTRODUCTION gears [2]. The modifications are more complex modifications of the flank
designed for the entire flank surface, but the surface. Formanufa
Gears are decisive components in transmission sys- example, sinusoidally shaped modifications
checked along a very limited number of lines on the sampled flanks. Especially for m have been
tems. The quality of the gears decides the performance investigated to reduce the noise levels of ground gears
neither along the profile nor along the helix direction, the conventional two-line meas
of the transmission system they construct, including [2]. The modifications are designed for the entire flank
the power transmission capacity, transmission accu- surface, but the manufactured gears are checked
racy, noise and vibration, reliability, and life time. The along a very limited number of lines on the sampled
geometry of the gears is controlled by quality inspec- flanks. Especially for modifications 2 applied neither
tion processes to ensure their conformance with the along the profile nor along the helix direction, the
design and tolerances. Until today, tactile measure- conventional two-line measurement will have difficul-
ments followed by a line-oriented evaluation proce- ties capturing the complete feature. Topography mea-
dure have been the dominant method to assess the surements could reveal the surface condition over a
deviations of gears from their nominal geometry. broader range of evaluation, but a quantitative assess-
During a tactile measurement, the probe physi- ment by deviation parameters is still based on line
cally approaches and contacts the preassigned nomi- evaluation, which is usually not sufficient to represent
nal points or scans along the prescribed lines in the the entire surface. In addition, topography measure-
profile and helix direction. Due to the tactile sensing ments of multiple teeth increase the measurement
August 2018     43
 In the three-dimensional model, the reference geometry of a cylindrical gear flank is an involute surf
with designed modifications [8–9]. The following assumes that the gear is aligned mechanically or
numerically. Given the coordinates of the sampled points measured on a flank surface, the deviation
determined as the distances from each measured point to the designed surface in the surface norma
direction. The plumb
time significantly, which is a critical disadvantage in production. line distance
2), based method [9] offers
on the coordinates a direct
of the and analytical
measured points andcalculation of such a dista
geometric
in required
Therefore, faster and area-based inspection techniques are the surface normal direction
parameters of(as
theillustrated
designedingear.
Figure 2), based on the coordinates of the measured
to fulfill the needs of modern gear metrology. points and geometric parameters
The plumb line of distance
the designed
fromgear.
an arbitrary measured point (index-
Optical sensing technology offers a high measuring The speedplumb ing j) to from
andline distance an involute an arbitrarysurface (on tooth
measured (indexingi) j)istogiven
pointnumber by
an involute surface (on tooth
generates a large amount of measured data, which has been number i) is given by
investi-
gated for gear measurement. Gear measuring instruments (GMI) and  2  s2  
rb  s j,i j,i 
coordinate measuring machines (CMM) have been equipped with dlot,um,j,i =  − 1 − tan−1  − 1  − γ j,i + Λ j,i 
2 2
1 + (tan β cos α t )2  rb  rb 
optical sensors, and integrated commercial devices were developed    
[3-6]. Tens of thousands to hundreds of thousands of measuring
Equation 1
points could be captured on each gear flank within a cycle time
where
comparable to the standard tactile measurement. These points cover ( s j,i , γ j,i , z j,i ) are the cylindrical coordinates 3 of point number j on tooth number i
17F
the entire flank (areal measurements) instead of two lines and can rb is the radius of the base circle
be captured on every flank surface of the gear, instead of four teeth αt is the pressure angle
only. This provides a solid base for the evaluation of the entire gear. β is the helix angle
Even though optical sensors provide high density data, the stan- Λ j,i is the rotational position where the involute starts on the base circle
dard profile and helix line analysis method can only offer evalu-
ations based on two-dimensional line features. The evaluation of Λ j,iLdepends on the z coordinate of the measured point and is related to the relative positions of
j,i depends on the z coordinate of the measured point and is
areal data requires a new mathematical approach that processes and right flank
related to the as well as the positions
relative index of the of measured
the left tooth.
andThe subscripts
right flank“lot” dlot,um,j,i denote
as inwell
plumb line distance. “um” clarifies that this plumb line distance equation is calculated with respect
three-dimensional surface points, characterizes them by areal fea- as the index of the measured tooth. The subscripts “lot” in dlot,um,j,i
“pure” involute surface as reference geometry. This means that it does not take into account any
tures, and correlates these features to attributes of the gear flanks denotes the plumb line distance. “um” clarifies that this plumb line
modification, referred to as “unmodified.”
with proper parameters. This paper describes an areal evaluation distance equation is calculated with respect to the “pure” involute
method, developed to fulfill these demands. Holistic parameters are With the plumb
surface as reference distance model,
geometry. the preassigned
This means nominal that points
it does are not
notnecessary
take into for the calcula
introduced to characterize an entire gear. distances. any
account Therefore, prescribed motion
modification, referred paths toare
asnot required and the uncertainties caused by im
“unmodified.”
nominal points are eliminated. Figure 2 illustrates the plumb line distances for a series of measure
on aWith gear flank.the plumb The red distance
dots represent model, the preassigned
the measured points, the nominal points
arrows represent the distances
2: AREAL DEVIATION MAP surface
are notnormal necessary direction,
forandthethe calculation
dark green dotsof ondistances.
the ideal surface are the corresponding
Therefore, pre- corr
OF A CYLINDRICAL GEAR FLANK nominal points.
scribed motion paths are not required, and the uncertainties caused
To assess the features of a measured gear flank in three-dimensional by improper nominal points are eliminated. Figure 2 illustrates the
space, its deviations from the designed (reference) flank geometry plumb line distances for a series of measured points on a gear flank.
are obtained first. In the line-based measurement of a cylindrical The red dots represent the measured points, the arrows d represent
gear, the reference geometries are two-dimensional lines. For exam- the distances in surface normal direction, and the dark green dots
ple, the reference geometry of a profile is where
an involute curve in the on the ideal surface are the corresponding correct nominal points.
transverse plane. The deviations are determined ( s j,i , γas z j,i )distances
j,i ,the are the cylindrical To be coordinates
consistentof withpointthenumber
generation j on tooth
principle numberandithe representa-
between the measured curve and the reference rb curve, is the measured
radius of the basetioncircleof deviations in conventional evaluation methods, va UVD coor-
u
perpendicularly to the reference curve. It is the direction of the line dinate system is constructed to present the deviations. Coordinate
αt is the pressure angle
of action and follows the generation principle of involutes. A devia- u is the generation Figure 2along
– Plumb theline distances
profile of measured
direction (rollpointslength, on awhich
gear flank
β is the helix angle and the representation in UVD coordinate system
tion chart is formed by plotting the deviations versus the position is the same for the conventional profile evaluation); coordinate v
Λ j,i is the rotational position where the involute starts on the base circle
of the measured point along the profile (usually the roll length). is the generation along the helix direction (z coordinate of the cor-
To be consistent with the generation principle and the representation of deviations in conventiona
In the evaluation procedure, a least-square mean profile is approxi- responding evaluation methods, nominala UVDpoint, which
coordinate system is the same fortothe
is constructed conventional
present the deviations. Coordina
mated, and deviation parameters are calculatedΛ j,i depends on the z coordinate
to quantitatively u is the
helix ofevaluation);
the measured
generation along point
the
coordinate andd
profile is
is related
direction to theofwhich
(roll length,
the amount relative
plumb is thepositions
same
line for of
thethe
distance. left
conventional p
evaluation); coordinate v is the generation along the helix direction (z coordinate of the correspon
andare
characterize the deviation plot. Modifications right
also flank as welland
identified as the index of the measured
The calculated plumb line tooth. The subscripts
distances collectively in dlot,um,
“lot” form j,i denotes
a distance map the
nominal point, which is the same for the conventional helix evaluation); coordinate d is the amou
plumb line distance.
included in the mean profile, described by modification “um” clarifies
parameters. plumbthat
of theline this plumb
measured
distance. Theline
flank distance
in theplumb
calculated
UVD equation
coordinate is calculated
line distances collectivelywith
system. This form respect
a distancetomap
map con- theof the
Modifications are intended alterations of the gear flanks, whereas
“pure” involute surface as reference tains
measured only
geometry.the distances
flank in theThis UVD means between
coordinate that the
it does
system. actual
Thisnotmap and
take nominal
into only
contains gear
account flank,
any between the
the distances
deviations are undesired errors of the actual gear. andanominal
so pure involute gear flank, so a pure
surface ininvolute surface in XYZ
XYZ coordinate coordinate
system system is equivalent
is equivalent to a to a fla
modification, referred to as “unmodified.”
zero d everywhere in the UVD coordinate system. Therefore, for an unmodified gear, whose refe
Several error sources introduce uncertainties in the evaluation flat with zero d everywhere in the UVD coordinate system. Therefore,
geometry is pure involute surface, the distance map contains undesired deviations only, which is
results. Firstly, the imperfections in motionWith
controlthe plumb
introduce distance
uncer- model,
for thean preassigned
analyzed unmodified
for the deviation nominal
gear, points
whose
parameters. are not necessary
reference geometry is forpure
the calculation
involute of
tainties, since the measured path might distances.
deviate from Therefore, prescribed
the target motion
surface, thepaths distanceare notmap required
contains and the uncertainties
undesired deviations caused by improper
only, which
nominalpoints pointsare areusually
eliminated.isFor a gear2with
Figure modifications,
illustrates the reference
the plumb geometry isfor
line distances notazero
series in theofdistance
measured map,points
since the d
transverse plane. Secondly, preassigned nominal analyzed for the deviation parameters.
flanks are different from involute surfaces. Modifications are three-dimensional surface-based fea
on a gear flank.
used for deviation calculations, while the probed points might not The red dots represent
theirFor the
a gearshould
definitions measured points,
with modifications, the arrows represent
the referencefeatures
be extended from two-dimensional geometry the distances
is not
to areal in
zeroas well. In ad
features
surface normal
be along the normal direction from these nominal points.direction, and in thethe
the dark
modification green
distance dots
mapon
features thebe
should
since ideal surface
specified
the designed in the are the corresponding
surface
flanks normal direction for
are different correct
three advantages
from
nominal points.
In the three-dimensional model, the reference geometry of a it agrees with
involute the direction
surfaces. of force transmission;
Modifications secondly, adding modifications
are three-dimensional surface-does not change
surface normal directions; thirdly, different modifications superimpose in the surface normal direct
cylindrical gear flank is an involute surface that they can be linearly combined to construct a designed surface. As a result, each modification
[7] with designed modifications [8–9]. The
following assumes that the gear is aligned 4 1
mechanically or numerically. Given the d
coordinates of the sampled points measured
on a flank surface, the deviations are deter-
mined as the distances from each measured
point to the designed surface in the surface
v
normal direction. The plumb line distance u
method [9] offers a direct and analytical
calculation of such a distance in the surface Figure 2: Plumb Figure 2 – Plumb
line distances of measuredline distances points on a of gearmeasured
flank and the points on a gear
representation in UVD flankcoordinate
normal direction (as illustrated in Figure system. and the representation in UVD coordinate system

44     gearsolutions.com
To be consistent with the generation principle and the representation of deviations in conventional
evaluation methods, a UVD coordinate system is constructed to present the deviations. Coordinate
 maps.

a) b) c)
Figure 3: Illustration of areal maps: a) plumb line distance map of measured points, b) designed modification map, c) deviation map
Figure 3 – Illustration of areal maps: a) plumb line distance map of measured points,
b) designed
based features, so their definitions should be modification map, c) deviation map
extended from two-dimensional features to
areal features as well. In addition, the modi-
3
fication Areal should
features Deviation and
be specified Modification Parameters for a Cylindrical Gear Flank
in the
surface normal direction for three advan-
To characterize a gear flank with areal features, area-based deviation and modification parameters are
tages: firstly, it agrees with the direction of
proposed
force to describe
transmission; secondly, these features quantitively. In this paper, they are defined in consistency with the
adding modifi-
meaning
cations does of
notthe corresponding
change the surface normal parameters in conventional gear evaluation. For example, in ISO 1328-1,
the profile slope deviation is defined as illustrated in the deviation plot of Figure 4. A mean profile line is
directions; thirdly, different modifications
superimpose in the surface normal direc-
constructed, and the intersections with the profile control diameter and tip diameter define the profile
tion, so that they can be linearly combined
slope
to deviation
construct a designed fHα .
surface. As a result,
each modification is a specific areal feature Figure 4 – Line-oriented evaluation of a deviation parameter:
added to the zero plane in the UVD coor- the profile slope deviation (ISO 1328-1)
Extended
dinate system,towhich
an areal
can beparameter
described byin the deviation map, the mean feature is a tilted plane instead of a line
awith slope function
continuous (see Figureof (u,v)5). The boundaries
coordinates. Figure 4: Figure 4 –evaluation
indicating
Line-oriented Line-oriented
the evaluation
of a deviation evaluation
range the
parameter: ofprofile
are atwo
deviation
planes
slope parameter:
deviation as
(ISOwell.
1328-1)The
the profile slope deviation (ISO 1328-1)
areal profile slope deviation can be defined as the distance between two facsimiles of the designed
Since the deviations are defined in the sur-
face normal direction as well, deviations and
surface, which are intersected by the mean surface at the profile control diameter and the tip diameter.
modifications are linearly added to form the
actualillustrations
The in words,
Figurethe5 modifi-
are based on a deviation map with profile deviations only. The deviation map
Facsimilie
surface. In other surface
is a three-dimensional
cations can be subtracted directly surface.
from the The black colored plane is the mean surface and is extrapolated to the
plane, indicating tip diameter, datum face, and non-datum face. The facsimiles of the designed surface
distance map to determine the undesired
deviations of a gear with modifications.
intersecting the mean surface are displayed. The areal profile slope deviation is marked in Figure 5b)
In conclusion, three different maps are
as
Facsimilie
surface
A
fHα , with
defined a superscript
to separate the deviationsʻAʼfrom
denoting
the the areal parameters.
designed features (intended modifications)
and to evaluate them as three-dimensional
areal features. Figure 3 offers an illustration
Cf u
of this procedure for an arbitrary sample:
The plumb line distance map consist- 5 17FTM08
ing of distances from measured points
to the unmodified pure involute surface FigureFigure
5 – A5:suggested definition
A suggested definition for
for the the corresponding
corresponding areal deviation areal deviation
parameter parameter
(corresponding (correspondin
to Figure 4):
a)top view showing the range of evaluation, b)side view showing f A A
(Figure 3a). to Figure 4): a) top view showing the range Cf of evaluation,
Ha b) side view showing fHα
u
The modification map, generated from
the designed areal modification parameters Theas assigned
similar in the can
definition draw- features
be applied to quantitively.
areal helix slope In this paper, they
deviation that itareis defined in consistency
also a plane, but tilted in the
ing, (Figure 3b). with the meaning of the corresponding
helix direction. Since all deviation features are defined in the surface normal direction parameters in conventional
and can be linearl
Figure 5of–the
The areal deviation map consisting A suggested
distances fromdefinition
mea- gear forevaluation.
the correspondingFor example, areal
in ISO deviation
1328-1, parameter (correspon
 superimposed and decomposed, a measured surface with both profile andthe profile
helix slopeslope devia- can be
deviations
A
sured points to designed modified flank surface to Figure
(Figure
represented 4): a)The
as3c).
the top view showing
areal
superposition tionofistwodefinedthe as
tilted range of
illustrated
planes. evaluation,
Other inthan
the deviationb) side
first order plot view
of showing
Figure
features, orderfHα
4. A mean
higher and
deviation map results from a direct subtraction of the first two maps. profile line is constructed, and the intersections
more complex features contained in the measured surface could be described independently in similar with the profile con-
manners, and then combined to trol diameter
depict data. define the profile slope deviation fHa .
and tip diameter
the measured
3: AREAL DEVIATION AND The MODIFICATION
similar definition can be applied toExtended areal helix to anslope
areal deviation
parameter that in theit deviation
is also a map,plane,thebut
meantilted in th
PARAMETERS FOR A CYLINDRICAL GEAR
helix direction.
Since FLANK
in Since
the all deviation
conventional features
evaluation,
featurethe isare defined
aprofile
tilted and
plane in instead
helixthelines
surface normal
area analyzed
of line direction
slope (see and
with separately, there
Figure can5).be
are line
cases
To characterize a gear flank with superimposed
arealwhere
features, and
differentdecomposed,
line-based
area-based a The
measured
devia-parameters surface
essentially
boundaries with both
represent
indicating thethe profile
same and
evaluation feature helix
range when
areslope deviations
theyplanes
two as can
are referred to
tion and modification parameters representedthe flank
are proposed as thesurface.
to describe Forthese
example,
superposition in conventional
ofwell.
two tilted
The arealplanes.line Other
profile evaluation,
than twist
slope deviation is
firstcan defined
order by two
features,
be defined separate
higher
as the order and
distance
parameters
more complex in profile
features and helixindirection.
contained the measured In the profile
surface direction,
could itbe is described
obtained byindependently
measuring one profile
August 2018     45in simila
near the datum face and another
manners, and then combined to depict the measured data. one near the non-datum face. The difference between the slopes of
these two profiles is defined as the twist in the profile direction. A similar procedure is applied for the twi
between two facsimiles of the designed surface, which are inter-
sected by the mean surface at the profile control diameter and the tip
diameter. The illustrations in Figure 5 are based on a deviation map
with profile deviations only. The deviation map is a three-dimen-
sional surface. The black colored plane is the mean surface and is
extrapolated to the plane, indicating tip diameter, datum face, and
non-datum face. The facsimiles of the designed surface intersecting
the mean surface are displayed. The areal profile slope deviation
is marked in Figure 5b) as fHa A with a superscript ‘A’ denoting the
areal parameters.
The similar definition can be applied to areal helix slope devia-
tion that it is also a plane but tilted in the helix direction. Since all
deviation features are defined in the surface normal direction and
a) b)
can be linearly superimposed and decomposed, a measuredFigure surface 6 –Figure
Twist definitions:
6: Twist a) twist
definitions: a) twist as illustrated
as illustrated in ISO 21771 [10],in ISO 21771 [10],
b) twist
with both profile and helix slope deviations can be represented as b) twistinrepresentation
representation the deviation map in the deviation map
the superposition of two tilted planes. Other than first order features,
higher order and more complex features contained in the measured
surface could be described independently In thein scope
similar of this paper,
manners
Holistic evaluation procedures and
and six deviation parameters are used to characterize the deviation
then combined to depict the measured data. parameters are needed to identify
including up to second order components in the map. The second order components are d
Since in the conventional evaluation, the profile and helix lines
are analyzed separately, there are cases crowning and twist
where different and quantify the repeated patterns
in the current ISO standard. Unfortunately, ISO does not clearly disting
line-based
parameters essentially represent thedeviations
same featureand when modifications
they
referred to the flank surface. For example, in conventional line evalu-
are
observed on all the teeth and to
for these components. They are included as deviation param
paper as well. in The sameand symbols as in ISO 1328-1 are used with an added superscript “A
ation, twist is defined by two separate
helix direction. In the profile direction,
parameters
it is obtained
profile
by measur-
establish global parameters that
areal parameters. Although serving as deviation parameters, the symbol “C” is used for cro
ing one profile near the datum face and another one near the non- represent the common condition of
deviations. The six parameters are, respectively, the cumulative pitch deviation, FpiA , the p
datum face. The difference between the slopes of these two profiles
deviation,
is defined as the twist in the profile direction. fHα
A similar procedure the entire gear.
A , the helix slope deviation, f A , the profile crowning deviation, A , the he
Hβ Cα
A
is applied for the twist in helix direction. Due to the arbitrary choice A
deviation, Cβ , and the twist deviation, S .Thus, each single flank surface is quantitively p
of measuring positions, it is common to see an unequal twist mea- deviations on each tooth, since they are repeated when cutting the
a seriesone
sured in profile and helix direction. However, ofparameter
deviationcould parameters.
individual teeth. These common patterns have direct correlation
represent this twist feature in the areal evaluation, since it describes with the systematic errors in the manufacturing process, and hence
a single second order surface, as illustrated in Figure 6. Face I is the should be identified and extracted.
datum face and II is the non-datum face. 4 Holistic Evaluation of an Entire
Secondly, except forGear
the repeated pattern, each tooth shows indi-
In the scope of this paper, six deviation parameters are used to vidual deviations that differ from tooth to tooth. They are caused by
The various deviations on gear flanks result from a diversity of error sources in the manufa
characterize the deviation maps, including up to second order com- varying machining conditions in manufacturing such as tempera-
processes. Two types of deviations
ponents in the map. The second order components are defined as
could be categorized in this procedure each having sp
ture gradients within the tool and the machined gear, vibrations,
correlations with
crowning and twist in the current ISO standard. Unfortunately, ISO the gear manufacturing
and inhomogeneous process andWhen
material. performance
combined with properties.
a mating gear,
does not clearly distinguish between deviations and modifications individual deviations result in changing contact conditions and
for these components. They are included Firstly, a repeated
as deviation parameters pattern
in could
shouldbe recognized
be taken on all teeth
into consideration, that is when
especially caused by errors
analyzing the imposi
this paper as well. The same symbols as influence on every
in ISO 1328-1 are usedtooth with during manufacturing.
performances For example, an error in the toolʼs pressure
of a gear pair.
an added superscript “A” to indicate the areal parameters. Although Therefore, holistic evaluation procedures and parameters are
introduces the same profile slope deviation on each tooth, since this tool cuts every tooth d
serving as deviation parameters, the symbol “C” is used for crown- needed to identify and quantify the repeated patterns observed on
machining. Positioning errors
ing deviations. The six parameters are, respectively, the cumulative
of the tool and systematic errors in the tool motion control le
all the teeth and to establish global parameters that represent the
A deviations A on each
pitch deviation Fpi , the profile slope deviation, fHa, the helix slope tooth, since
commontheycondition
are repeated whengear.
of the entire cutting
In thetheconventional
individual evalu-
teeth. These
A patternsChave
deviation, fHb , the profile crowning deviation, A directcrown-
a, the helix correlation
ation,with
where the 16systematic
lines on fourerrors
teeth are in measured,
the manufacturing
the extraction process, an
shouldSAbe
ing deviation, CbA, and the twist deviation, identified
. Thus, and extracted.
each single of a repeated pattern observed on all the teeth has never been
flank surface is quantitively presented with a series of deviation reported. The current gear standards do not separate global gear
parameters. Secondly, except for the repeated pattern,parameters and individual
each tooth toothshows
parameters either. Indeviations
individual the context that diffe
of this paper, five global parameters are calculated and presented
4: HOLISTIC EVALUATION OF ANtooth. ENTIRE They GEARare caused by varying machining conditions in manufacturing such as tempera
for the measured gear sample in Section 6. They are identified with
within the tool and the machined
The various deviations on gear flanks result from a diversity of “g” subscriptions, gear, vibrations,
which are and inhomogeneous
the global material.
profile slope deviation, fHagWhen
A, com
mating gear,
error sources in the manufacturing processes. individual
Two types of devia-deviations
the globalresult
helix in changing
slope deviation, contactA
fHbg , theconditions
global profileand should be take
crowning
consideration,
tions could be categorized in this procedure each having especially
specific when analyzing
deviation, CagA, the the performances
global helix crowning of a gear pair.
deviation, CbgA, and the
correlations with the gear manufacturing process and performance global twist deviation, SgA.
properties. Therefore, holistic evaluation procedures and parameters are needed to identify and quan
Firstly, a repeated pattern could be recognized on all teeth that is 5: MATHEMATICAL APPROACHES FOR AREAL
repeated patterns observedAND
caused by errors imposing the same influence on every tooth during
on all the teeth
HOLISTIC and to establish global parameters that repres
EVALUATION
common condition
manufacturing. For example, an error in the tool’s pressure angle of the entire gear. In the conventional
With the deviation map of each tooth evaluation,
obtained as where 16 lines
explained in on fou
measured,
introduces the same profile slope deviation the extraction
on each tooth, since this ofSection
a repeated pattern observed
2, the evaluation on all the teeth
procedure characterizes has never
the surface, offer- been re
tool cuts every tooth during machining. current gear standards
Positioning errors of thedo not separate
ing the global gear
areal parameters parameters
as explained and3individual
in Sections tooth param
and 4. Different
the context
tool and systematic errors in the tool motion controlof thisthepaper,
leave same five global
surface parameters
analyzing approachesare could
calculated
be appliedandtopresented
quantify thefor sur-the meas
46     gearsolutions.com
 d the global twist deviation, SgA .

oaches face
forfeatures
Areal within
and Holistic Evaluation
the deviation map, which focus on the construc-
tion of the “mean surface,” also referred to as a “reconstruction” of
ch tooth obtained as explained in Section 2, the evaluation procedure
the deviation map in this paper.
fering the areal parameters as explained in Section 3 and 4. Different surface
be applied to APPROXIMATION
5.1: quantify the surfaceOFfeatures within the MAP
THE DEVIATION deviation map, which
the “meanTosurface”, also referred to as a “reconstruction” of the deviation
obtain a “mean surface” from the deviation map, a two-dimension-
al approximation could be carried out taking the deviation map as a
polynomial function of u and v coordinates. For the five parameters
e Deviation Map
in this paper, the highest order polynomial terms included are sec- · Custom gear racks in AMERICAN and
ond order terms, describing the profile crowning, the helix crowning, METRIC standards, STRAIGHT and
rom the deviation map, a two-dimensional approximation could be carried out HELICAL, VARIOUS materials, FINE
and the twist. Therefore, the approximated surface takes the format
a polynomial function of u and v coordinates. For the five parameters in this and COARSE pitch (254 D.P. – 0.5 D.P.;
of a second order polynomial of u and v. Different objective func- 0.10 Module – 50 Module); hard-cut
nomial terms
tions included are second
could be used, where theorder terms,
L2-norm describing
of the the
deviations at profile
all the (up to 60 Rc) and soft-cut (up to 40
, and the measured
twist. Therefore, the approximated surface takes the format of a
points is one of the most widely used objective functions. Rc); 32” face width; Up to 82” lengths
u and v . ItDifferent objective
is consistent functions
with the could
conventional beevaluation
line used, where
methodtheand
L 2 -norm
is of – longer lengths through resetting
sured points is one of the most widely used objective
relatively well understood for uncertainty estimation.functions. It is · Custom gears in AMERICAN and
METRIC standards (3 D.P. – 72 D.P.,
onal line evaluation
With themethod and is relatively
“mean surface” obtained,well
the understood for uncertainty
deviation parameters 10” Diameter)
could be calculated from the coefficients of the approximated poly- · Precision Quality up to AGMA 12
nomial directly. The quantitative values of the deviation parameters · Prototype & Production quantities
ained, the deviation
are parameters
then derived from the could be calculated
geometric from
relations in the the coefficients
parameter defi- of · Breakdown Service Available
nitions (for example, the geometric relations in Figure 5). · Reverse Engineering
l directly. The quantitative values of the deviation parameters are then · Unique Tooth Configurations
elations in the parameter definitions (for example, the geometric relations in · Heat Treating
5.2: SURFACE COMPONENTS DECOMPOSITION · Complete CNC Machining
WITH ORTHOGONAL POLYNOMIALS
An alternative approach is based on a series of orthogonal polynomi-
s Decomposition with Orthogonal Polynomials
als, which describes an arbitrary surface as a linear combination of
ased on atheseries of orthogonal
individual polynomials,
terms. In other words, thewhich
surfacedescribes an arbitrary
can be decomposed
on of theinto
individual
a series terms. In other
of orthogonal words, thewhere
polynomials, surface
eachcan
termbereveals
decomposed
a
olynomials, wherefeature
specific each in term
thisreveals
surface.aTwo-dimensional
specific feature Chebyshev
in this surface.
poly- Two-
nomials are one example
nomials of suchofpolynomial
are one example series, series,
such polynomial which which
are orthogonal
are on
orthogonal on the domain of [-1,1]x[-1,1]. Equations 2 to 7 offer
. Equations 2 to 7 offer the mathematical representations of the first six terms the
mathematical representations of the first six terms as functions of
x and ytwo
. The subscripts
variables x and y.are
thethe commonly
subscripts used
are the indicesused
commonly of the two-
indices
ms. of the two-dimensional Chebyshev terms.
C0 ( x , y ) = 1 Equation 2 (2)

C1 ( x , y ) = x Equation 3 (3)

C2 ( x , y ) = y Equation 4 (4)

C3 ( x , y ) = 2 x 2 − 1 Equation 5 (5)

C 4 ( x , y ) = xy Equation 6 (6)

C5 ( x ,=
y ) 2 y2 − 1 Equation 7 (7)

One of the major advantages of using Chebyshev polynomials

s of usinginChebyshev polynomials in analysis of gear flank surfaces is that
analysis of gear flank surfaces is that they describe equivalent
ures as represented by the gear
features as represented flank
by the deviation
gear parameters
flank deviation [11]. [11].
parameters Direct
efficients of Chebyshev
Direct terms
correlations and the
between thegear deviation
coefficients of parameters can then be
Chebyshev terms
igure 7 offers
and thea comparison
gear deviation ofparameters
Chebyshev polynomials
can (updue
then be found to the second
to this
g gear flank features.
similarity. The7“2D
Figure Chebyshev
offers a comparisonPolynomials”
of Chebyshevcolumns offer the
polynomials
polynomials(up and
to thethe “Gear
second Flank
order) andDeviation Parameters”
the corresponding columns
gear flank offer both
features.
parameters Theon“2D
a gear flankPolynomials”
Chebyshev in 3D spacecolumns
and theoffer
corresponding
the diagramsdeviation
of the map
Chebyshev polynomials and the “Gear Flank Deviation Parameters”
columns offer both the illustrations of the areal parameters on a gear
flank in 3D space8and the corresponding deviation map in the UVD17FTM08
coordinate system. Comparing the Chebyshev polynomial maps with
the deviation maps in UVD coordinate system, the gear flank devia-
tion parameters could be expressed as functions of the coefficients 421 SE Bailey Road • Lee's Summit, MO 64081
of the Chebyshev terms. The comparisons here are qualitative, thus
the scales are not specified. Extrapolation rules are not included in
Figure 7.
August 2018     47
 coefficients of the Chebyshev terms. The comparisons here are qualitative, thus the scales are not
specified. Extrapolation rules are not included in Figure 7.

in the UVD
tem. Comparing thecoordinate
Chebyshevsystem. Comparing
polynomial the Chebyshev
maps with polynomial
the deviation maps in maps with the deviation maps in
UVD coordinate system, the gear flank deviation parameters
he gear flank deviation parameters could be expressed as functions of could
the be expressed as functions of the
coefficients
hev terms. of the Chebyshev
The comparisons here areterms. The comparisons
qualitative, here
thus the scales areare
notqualitative, thus the scales are not
les are specified. Extrapolation
not included in Figure 7.rules are not included in Figure 7.

Figure 7: Comparison of Chebyshev polynomials and areal gear deviation parameter definitions
Figure 7 – Comparison of Chebyshev polynomials and areal gear deviation parameter definitions
The second advantage of Chebyshev polynomials is the orthog-
Figure polynomials
of Chebyshev 7 – Comparison
andof Chebyshev
areal gear polynomials
deviation and areal gear deviation parameter definitions
As explained in Section 2, theparameter
deviations definitions
The second advantage of Chebyshev polynomials is the orthogonality property. As explained in Section 2,
onality property. are all
defined in the surface normal direction of the flank. In addition,
the
Thedeviations
second are
advantage all
of defined
Chebyshev inproperty.
the surface
polynomials is thenormal direction of the flank. Inin addition,
Section 2, they are independent
Chebyshev
they polynomials
are independentis theand
orthogonality
linearly combined toAs the orthogonality
explained
form in Section property.
deviation 2, As explained
ned in and
the
map. linearly
thesurface
deviations combined
are
normal
Therefore, allChebyshev
defined
direction
the toin
of form
thethe
flank. the
surface deviation
normal
In addition,
polynomials map.
direction
could they
serve are of Therefore,
the the Chebyshev
effi-flank. In addition,
as independent
an polynomials could serve as
they are independent
an
orm the and linearly
efficient
deviation combined
map.tool to to form
decompose
Therefore, the the deviation
Chebyshev the map.
measuredTherefore,
polynomials
cient tool to decompose the measured deviation map, offering the the
deviation
could Chebyshev
serve as map, polynomials
offering could
the serve as
coefficients of the six terms listed
pose the an efficient tool
measured to decompose
deviation map, the measured
offering the deviation
coefficients of map,
the six offering
terms the coefficients of the six terms listed
listed
ininFigure
coefficients 7. The decomposition could be expressed mathematically by Equation 8.
of the six terms listed in Figure 7. The decomposition
Figure 7. The decomposition could be expressed mathematically by Equation 8.
sition could
couldbebeexpressed
expressedmathematically
mathematicallybybyEquation
Equation8.8.

D ( x , y ) = ∑ ApC p ( x , y )
p
( ) ∑ Ap(8)C p ( x , y )
D ( x , y ) = ∑ ADpC pEquation
x(,xy, y )= 8 (8) (8)
p p
where a) a) b) b)
where
iation map D ( x , y ) is the deviation map Figure
Figure
8 – Optical
8 –Figure
Optical
gear measurement:
gear
8: Optical gearmeasurement:
measurement:a)a) HN-C3030
a) HN-C3030
HN-C3030 optical
optical optical
measuring
measuring measuring
device; b) device;
de
D( x, y) is the deviation map b) measured
b) measured
measured pointpoint point
clouds
clouds obtainedclouds
obtained
from a gearobtained
from from
sample a geara sample
gear sample
isterm
Ap Chebyshev
fficient of the the coefficient
indexing pof the Chebyshev term indexing p
left or right flanks of all teeth, for example, offers an estimation of
ebyshev term is Chebyshev
ACpp indexing pis the the coefficient of areal
An the
AnpChebyshev
term indexing areal
measurementterm
measurementindexing
on all
the on
teeth
common pprofile
all teeth
was conducted
was slope
conducted
on a CMM
on of
deviation a the
CMM
to compare
to compare
entire the
gear. In results
thecase,
this results
with the
with
o
measurements.
measurements. 51 profile
51 profile
lines
it willacross
lines across
the flank
be reasonable the surface
flank surface
to consider were
the leftmeasured
were measured
and right on each
flank on flank
each of
parameter flank
all tee
of a
5.3
s of Individual Statistical
Parameters Analysis of Individual Parameters for Holistic Evaluation
5.3:
C pSTATISTICAL isfor
the Holistic
ANALYSISChebyshevEvaluation term indexing p
OF INDIVIDUAL separately, since there might be different deviations on the left and
PARAMETERS
Each individual
be evaluated FORof
with eithertooth
one HOLISTIC
canthebementioned
evaluatedEVALUATION
with either one
algorithms, of theinmentioned
resulting algorithms,
a list of right resulting
cutting edge of theintool.
a listWhen
of trends or a certain distribution of
individual
each tooth.
EachAs parameters
explainedtooth for
in Section each tooth.
can be4,evaluated As
the repeated explained
withpattern in
either is Section
to of
bethe 4, the
recognizedrepeated pattern is to be recognized
5.3 Statistical
individual
from allofteeth Analysis
to represent of Individual Parameters
one
for Holistic Evaluation
men- the individual parameters are discovered, changing machining condi-
the condition
tioned the entire
algorithms, gear in the
resulting condition
its totality.
in ofofindividual
a listThe the entire
holistic gear
evaluationin its
parameters totality.
aimsforat Thetionsholistic evaluation
or errors aims atfrom tooth to tooth will be revealed.
that propagate
finding
onable summary a of
proper
the and reasonable
information invalid summary
for all of the information
teeth. pattern isvalid
to befor all teeth.
Each individual tooth can be evaluated with either one of the mentioned algorithms, resulting in a list of
each tooth. As explained Section 4, the repeated
individual parameters for each tooth. As explained in Section
recognized from all teeth to represent the condition of the entire gear 5.4: ALIGNING AND COMBINING
4, the repeated pattern isFLANK
to be SURFACES
recognized
in its totality. The holistic evaluation aims at finding a proper and FOR HOLISTIC EVALUATION
from all teeth
reasonable summaryto represent the condition of9the
9 of the information valid for all teeth.
entire gear
17FTM08
Statistical in its totality. The holistic
teeth are described byaims
17FTM08
The relative positions of the evaluation singleat
pitch devi-
finding
analysisa onproper and
individual reasonable
parameters summary
could offer of assessment
a reasonable the information
ationsvalid for all teeth.
or individual cumulative pitch deviations. The individual
for the entire gear. The average of the profile slope deviations on all cumulative pitch deviations of all teeth are their positioning errors
48     gearsolutions.com
9 17FTM08
An areal measurement on all teeth was conducted on a CMM to compare the results with the optical
measurements. 51 profile lines across the flank surface were measured on each flank of all teeth.

displayed in Table 1. The same procedure was applied for the other three global parameters. The
average value of the two twist parameters calculated in profile and helix direction is taken as the global
twist value.

Table 1 – Results of three different measurements and evaluations in arbitrary order: areal
Figure
Figure99: – Deviation
Deviation
evaluation of the maps
mapsoptical
with first 7 teethof
measured the
obtained
data, byfirst
arealtactile 7 teeth
measurement,
evaluation obtained
original
with tactile deviationby
measured maptactile
data, andrepeatedmeasurement,
and pattern original deviation
conventional line-oriented evaluation
map and repeated pattern ters in this method is to evaluate and remove
Parameter Symbol Measurement A Measurement B Measurement C
the pitch deviations correctly. Some difficul-
Profile slope A
fHαg or fHαg -1.0 -0.8 -0.2
ties might be caused by the large amount
deviation (μm)
FigureHelix
9 shows
slope
the evaluation
A
results of the tactile areal data. The dots with
of color
input gradients
data during show calcula-
the numerical the
fHβg or fHβg -5.2 -4.9 -3.7
original deviation maps of the first 7 teeth. An obvious common pattern of crowning in the helix direction
deviation (μm) tions. For example, the computation time
might be increased significantly.
could be recognized. The
Profile crowning
(μm)
A
Cαg orredCαg surfaces 0.6show the “mean 0.2 surface”, -0.1 which are the reconstructed repeated

patternHelix
determined
crowning with Chebyshev method. It could also be noticed that6:the repeatedOFpattern
EVALUATION has
BOTH OPTICAL
different offsets from the original deviation map except the first tooth. This misalignment is causedDATA AND TACTILE MEASUREMENT
A
Cβg or Cβg
(μm) 6.9 6.8 6.9
by the
AND COMPARISONS
cumulative pitch deviation
Twist (μm)
of each tooth
SgA or Sg 10.0
as explained 11.0
in Section 9.3
5.4, which is not
A series included inandthe
of measurements repeated
evaluations
pattern since they are individual deviations of each flank. The areal deviation parameters
was carried calculated
out to implement with
the areal and
the holistic evaluation procedure described in Section 5.2 and 5.3 are also listed in Table 1.
Table
Table 1:
1 Results
consistsof
ofthree different
results of measurements
three different and evaluations
measurement and in arbitrary
evaluation order: areal
processes. evaluation
One of themwith holistic evaluation method. The same gear
represents the result
optical measured data,ofareal
a conventional line-oriented
evaluation with inspection
tactile measured data,procedure. The other
and conventional two are based
line-oriented on
evaluation. sample was measured using both tactile
areal measurements and evaluations, one of them based on tactilely probed data and the other on measuring devices and optical instruments.
Conventional line-oriented measurements and evaluations were also carried out using both GMIs and
optically measured data. It could be discovered that the three different measurements and evaluation
with respect to the same reference flank. It is an individual tooth Some of the tactile inspections were based on conventional line-
methods result in variations of the deviation parameters. For the experiments reported here, the five
CMMs to compare the results with areal evaluations. The deviation parameters from one of the standard
parameterparameters
investigated in the areal evaluation,
vary within 2 μm.which is different
The differences andresult
might unique for
from: oriented measurements and evaluations. Areal measurements were
each flank. In the measured flank data, it is contained as a uniform realized (i) by scanning multiple lines across the surface of all teeth
measurements
– Different are
offset from the listed
sampling
reference in Table
conditions:
geometry across 1. the
Four
the line evaluation
entireteeth
is based were
on samples
flank in the measured
in
tactilewith
one profile or helix
using
line a profile line and a helix line on each
instruments and (ii) with an optical instrument per-
on the surface, whereas the areal evaluation is based on a larger number of points covering the
flank for the
surface slope
normal
entire of and
area direction. crowning
each flank,The parameters.
corresponding
all teeth involved. feature inTwo profileforming
the devia- lineshigh anddensity
two laser
helix lines The
scanning. weregearmeasured on each
sample was a ground
flank of –the first definitions
tooth to calculate and the twist.
tion map is a plane, related to the 0th term of the two-dimensional
Different
Chebyshev
of area-based line-based The For
deviations: average
example, theofconventional
four profile slope deviations of the right flanks
automotive gear, which is not a calibrated artefact. Therefore, the
profileterm (referare
deviations to defined
Figure in7)the
if evaluated with perpendicular
transverse plane the algorithm results curve,
to the involute presented
whereashere are not compared to access the performances
are taken as the
the areal
explained in global
deviations
Section profile
5.2.are defined on slope
the entire deviation
surface in the to compare
surface normalof with
direction.
the thoseinstrument,
measuring calculated from
but to theoutcomes
show the areal data. Only
of the areal
right flanks
The are used
pitch
– Different deviations here,
approximationdo not since
methods: thethe
contribute arealparameters
to the
line-oriented evaluations
repeated pattern arebased
are evaluatedand conducted
holistic on all right flanks for the resultsare
evaluations.
on least- Algorithms introduced in 5.2 and 5.3
for all teeth.
square If theyorare
profile quantified
helix and the
lines, whereas removed from theisdeviation
areal evaluation used toorthogonal
based on Chebyshev achieve the results listed in this section.
polynomials.
maps, the flank positions will be corrected so that every flank will A Nikon HN-C3030 is used to obtain optical areal data.
be –present at its
Different nominal position
measurement conditions:relative
the geartowasthe reference
measured flank. instruments
on different Approximately 480,000 points were measured on each flank includ-
by different
operators
Since the nominal under differentoflab
position conditions.
a flank is known, it can be rotated by 11 ing parts of the top and bottom lands and the datum and non-datum17FTM08
a certain angle to be duplicated at the position of the reference flank. faces. About 105,000 points were identified as valid evaluation points
7By aligning
Conclusions
all teeth andtoFuture Work position, a combined surface
the reference within the evaluation range on each flank. The device and the
consisting
Modern gear of all measured
production requirespoints on all flanks
advancements is constructed.
in inspection a faster obtained
techniques:This and more point data cloud are shown in Figure 8.
comprehensive
surface contains measurement as well as
all the deviation an improvedof
information evaluation. The shiftthe
the gear (except of perspective
An to three-
areal measurement on all teeth was conducted on a CMM to
dimensional
cumulativedesign
pitchand modeling, areal
deviations), suchmeasurement,
that the set and holistic deviation
of global evaluation are compare
some of the most
the results with the optical measurements; 51 profile lines
significant
parameters improvements
(see Section in gear metrology. Theythis
4) characterizing form combined
the basis forsurface
innovative
is solutions
acrossofthe
dataflank surface were measured on each flank of all teeth.
interpretation, including improved manufacturing process assessment, and functional performance
a fully sufficient representation of the entire gear.
investigation. This paper presented:
Figure 9 shows the evaluation results of the tactile areal data. The
The prerequisite to ensure the effectiveness of the global parame- dots with color gradients show the original deviation maps of the
– Definitions of deviations in a three-dimensional gear model and the construction of areal deviation
maps,
August 2018     49
– Suggestions to define extended deviation and modification parameters, covering also areal
measurements and evaluations, and their meaning in terms of surface features,
 first seven teeth. An obvious common pattern of crowning in the
helix direction could be recognized. The red surfaces show the “mean
surface,” which are the reconstructed repeated pattern determined
with Chebyshev method. It could also be noticed that the repeated
pattern has different offsets from the original deviation map except
the first tooth. This misalignment is caused by the cumulative pitch
deviation of each tooth as explained in Section 5.4, which is not
included in the repeated pattern since they are individual deviations
of each flank. The areal deviation parameters calculated with the
holistic evaluation procedure described in Sections 5.2 and 5.3 are
also listed in Table 1.
Conventional line-oriented measurements and evaluations were
also carried out using both GMIs and CMMs to compare the results
with areal evaluations. The deviation parameters from one of the
standard measurements are listed in Table 1. Four teeth were mea-
sured with a profile line and a helix line on each flank for the
slope and crowning parameters. Two profile lines and two helix
lines were measured on each flank of the first tooth to calculate
the twist. The average of four profile slope deviations of the right
flanks are taken as the global profile slope deviation to compare
with those calculated from the areal data. Only right flanks are
used here, since the areal evaluations are conducted on all right
flanks for the results displayed in Table 1. The same procedure was
applied for the other three global parameters. The average value of
the two twist parameters calculated in profile and helix direction
is taken as the global twist value.
Table 1 consists of results of three different measurement and
evaluation processes. One of them represents the result of a conven-
tional line-oriented inspection procedure. The other two are based
on areal measurements and evaluations, one of them based on tac-
tilely probed data and the other on optically measured data. It could
be discovered that the three different measurements and evaluation
methods result in variations of the deviation parameters. For the
experiments reported here, the five investigated parameters vary
within 2 μm. The differences might result from:
Different sampling conditions: the line evaluation is based on
samples in one profile or helix line on the surface, whereas the areal
evaluation is based on a larger number of points covering the entire
area of each flank, all teeth involved.
Different definitions of area-based and line-based deviations:
For example, the conventional profile deviations are defined in the
transverse plane perpendicular to the involute curve, whereas the
areal deviations are defined on the entire surface in the surface nor-
mal direction.
Different approximation methods: the line-oriented parameters
Booth N-237024 are evaluated based on least- square profile or helix lines, whereas

Speed up your
the areal evaluation is based on Chebyshev orthogonal polynomials.
Different measurement conditions: the gear was measured on
different instruments by different operators under different lab

productivity conditions.

CONCLUSIONS AND FUTURE WORK

with our trio wheels! Modern gear production requires advancements in inspection tech-
niques: a faster and more comprehensive measurement as well as an
improved evaluation. The shift of perspective to three-dimensional
design and modeling, areal measurement, and holistic evaluation
are some of the most significant improvements in gear metrology.
KAPP Technologies They form the basis for innovative solutions of data interpretation,
including improved manufacturing process assessment, and func-
kapp-niles.com info@kapp-niles.com (303) 447-1130 tional performance investigation. This paper presented:
Definitions of deviations in a three-dimensional gear model
and the construction of areal deviation maps.
50     gearsolutions.com
072018_halfpage_TrioWheels_1.indd 1 6/22/2018 2:34:36 PM
 Suggestions to define extended deviation and modification

parameters, covering also areal measurements and evaluations, and
their meaning in terms of surface features.
Holistic evaluations of entire gears as an integration of informa-

tion obtained from all teeth.
Effective algorithms to conduct areal and holistic evaluations.

Comparisons of different evaluation processes on a gear sample

to show the capability of the current algorithms.
The scope of future research work will comprise:
Measurements and evaluations of a calibrated artefact using

different instruments leading to traceable assessments of the mea-
suring devices and algorithms.
Additional surface analyses, approximation, and reconstruction

algorithms.
Modeling of complex modifications, correlation of parameters

to manufacturing processes, and interaction between tooth flanks
at meshing based on areal gear flank data. 

REFERENCES
[ 1 ] ISO, 2013, “Cylindrical gears – ISO system of flank tolerance classification
– Part 1: Definitions and allowable values of deviations relevant to flanks of
gear teeth,”, ISO 1328-1.
[ 2 ] Mehr, A. E., Yoder, S., 2016, “Efficient Hard Finishing of Asymetric Tooth
Profiles and Topological Modifications by Generating Grinding,” AGMA Fall
Technical Meeting, American Gear Manufacturers Association, Pittsburg
(PA), USA
[ 3 ] Nikon HN-C3030, “Non-contact sensor 3D measuring system,” from <http://
www.nikon.com/products/industrial-metrology/lineup/3d_metrology/3d-
coordinate- metrology/hnc3030/>
[ 4 ] Gleason, “300GMSL Multi-Sensor Inspection System,” from <http://www.
gleason.com/products/3984/354/300gmsl>
[ 5 ] MS3D, “3D Inspection of Gear,” from <http://www.ms3d.eu/en/our-
machines/3d-inspection-of-gear- gearinspection/>
[ 6 ] Hexagon Metrology, “Optical Sensor HP-O,” from <http://www.hexagonmi.
com/- /media/Hexagon%20MI%20Legacy/hxmt/Leitz/general/brochures/
HP-O%20with%20Leitz%20PMM- C%20Brochure_en.ashx.>
[ 7 ] W. Lotze, F. Haertig, 2001, “3D Gear Measurement by CMM,” Fifth
International Conference of Laser Metrology and Machine Performance
(LAMDAMAP), WIT Press, pp.333–344.
[ 8 ] Pfeifer T., Napierala A., Mandt D., 2002, “Functional Orientated Evaluation
Find out more at
of Modified Tooth Flanks,” VDI-BERICHTE NR. 1665, 769–783.
[ 9 ] Goch, G.; Günther, A., 2006, “Areal gear flank description as a requirement
for optical gear metrology,”. Towards Synthesis of Micro /Nano-Systems,
The 11th International Conference on Precision Engineering (ICPE) August
16–18, 2006, Tokyo, Japan, pp. 47–52.
[ 10 ] ISO, 2007, “Gears – Cylindrical involute gears and gear pairs – Concepts
and geometry,” ISO 21771.
[ 11 ] Ni, K., Peng, Y., Goch, G., 2016, “Characterization and evaluation of invo-
lute gear flank data using an areal model,” 31st ASPE Annual Meeting,
American Society for Precision Engineering, Portland, 2016, pp. 184–189.
Booth #237024
North, level 3
ABOUT THE AUTHOR

Yue Peng, Kang Ni and Dr. Gert Goch are on the faculty of the
University of North Carolina at Charlotte. Visit www.uncc.edu. KAPP Technologies
Copyright© 2017 American Gear Manufacturers Association, ISBN:
978-1-55589-578-5, 17FTM08. The statements and opinions kapp-niles.com info@kapp-niles.com (303) 447-1130
contained herein are those of the authors and should not be construed
as an official action or opinion of the AGMA. Go to www.agma.org.

August 2018     51

082018 KappAd_IMTS_HalfPage_GS.indd 1 7/20/2018 3:49:51 PM

 MODULAR
SEALING
SOLUTION
IDEAL FOR
AUTOMATION

52     gearsolutions.com
An innovative sealing system has been developed
especially for industrial applications where robustness
and long lifespans of gears are in demand, including
robots and automation.
By MARCEL SANTOS and BENJAMIN KOHL
A
cross every industry, today’s state-of-the-art
manufacturing environment emphasizes vari-
able batch sizes, flexible processes, and high
availability. These factors are placing higher
demands on individual components, including gear
motors, in the manufacturing process. Used to drive
conveyor belts and assembly lines, the longevity and
strength of gear motors are critical factors in increas-
ing productivity and improving operations. Innovative
engineering by Freudenberg Sealing Technologies
has resulted in the MSS 1 (Modular Sealing Solution),
which significantly increases the life and energy effi-
ciency of gear motors, thus delivering higher produc-
tivity and optimizing manufacturing operations.
‘NEW’ SOLUTION WITH 20-YEAR HISTORY
For 20 years, a combined unit consisting of a
Simmerring® Shaft Seal (radial shaft seal or RSS) and
a second sealing ring with a sinus-shaped seal lip
has proven its effectiveness in gear
motors with remarkable reliability
and success. Developed in collabora-
tion with a major engineering drive
manufacturer, Freudenberg’s seal-
ing solution targeted applications
with slow rotating shafts where
robustness and long component
performance were critical to indus-
trial operations. The system has now
become an industrial standard — a
sealing success founded on careful
analysis, understanding and then Figure 1: The MSS 1-HS high speed
designing what customers require to seal was developed to function in
maintain the productivity and profit- fast rotating, highly dynamic motors.
ability of their systems. Importantly,
as industrial operations have evolved, Freudenberg
engineers have continued to refine this unique sealing
system and have now introduced a new system design
for use on the high-speed gear input shafts. This MSS
1-HS (High Speed) seal offers the industry the same
standard of sealing reliability and extended lifespan of
the MSS 1 seal, with the added benefit of functioning
in fast rotating, highly dynamic motors.
ENGINEERING THE INNOVATIONS
In industrial drive systems, there are ever-increasing
stresses created due to varying rotational speeds, alter-
nating rotational directions and frequent startup pro-
cedures. It is critical that the radial shaft seal ring — a
component whose performance and service contribu-
tions to the system are frequently overlooked – reliably
seals the gear unit to prevent oil leakage and environ-
mental contamination in both rotational directions.
The modular sealing system combines two seals
into a single component. This approach results in less
friction and a reduced need for axial installation space
compared with the standard double seal design, which
features a primary seal and a redundant secondary
seal. This design further results in greater robustness
than a single radial shaft seal ring, providing built-in
backup to the primary seal and significant risk reduc-
tion.
The RSS, acting as a secondary seal, is friction-opti-
mized, has a dust lip and a smooth, rubberized adher-
ing piece for a secure fit in the housing. As a standard
option, it can be made from fluorocarbon rubber 75
FKM 585 or nitrile rubber 72 NBR 902, depending on
the application or demand. A grease reservoir contain-
ing lubricant is attached between the
dust lip and the seal edge to provide
lifetime lubrication. The RSS is com-
bined with the primary seal whose
seal lip is made of 75 FKM 585.
An important special feature of
the sealing system is the seal lip’s
sinus-shaped line of contact on the
shaft. The sinus shape serves as a
bi-directional conveyor structure,
distributing the lubricant in the seal
gap with a wiping effect that is signifi-
cantly more effective than a standard
seal lip with a traditional straight line
of contact. Any dirt particles in the
system are kept away from the seal
edge, thanks to the continual exchange of lubricant,
eliminating contamination, reducing wear and signifi-
cantly extending the lifespan of the gears.
Manufacturers can expect up to 20,000 in-service
hours or more with this solution — under certain cir-
cumstances, as much as 30 percent longer than stan-
dard seals, within specific parameters and controlled
applications. The design of the system also reduces
friction by as much as 60 percent, depending upon
the application, resulting in lower operating tempera-
tures and related less wear. It also increases energy
efficiency with up to 60 percent less power loss when
it is applied.
Additionally, as the system does the work of two
August 2018     53
conventional seals, maintenance require-
ments are reduced and production processes
Today’s global manufacturing environment requires
are optimized that lead to a reduction in the optimization of every component and every process.
overall cost of operations for a manufacturer.
Global design and the need for economies of scale
INDUSTRIES AND APPLICATIONS
Widely varied industry applications and are driving standardization. Nonetheless, regional
varying parameters mean that a precise cal-
culation of the lifespan of radial shaft seals
customization is often necessary to meet various
is not possible, but it is impressive to note Fig. 2:
regulatory requirements.
that during Freudenberg’s 20-year technol-
ogy partnership with the drive manufac-
turer, more than 3 million MSS 1 sealing
systems were used in gear motors without
a single return from the field.
Efforts to replicate this success for high
speed applications required innovation and
design changes. Because the use of this seal-
ing system is limited by a 6 m/s maximum
achievable circumferential speed, engi-
neers focused on a primary goal: reducing
the mechanism’s friction and temperature
development to deliver greater longevity
and energy efficiency at high rotational
speeds.
To achieve this, engineers focused on
three key development initiatives. First,
they reduced the contact pressure on the
shaft at the sealing edge of the outer RSS by
using a specially designed spring. Then, they
enlarged the diameter of the dust lip so that
it no longer has direct contact with the shaft
which is not required on the motor side.
Finally, they installed an additional grease
reservoir between the two RSS for lifetime
lubrication. With these innovations, the
Fig. 3:
Figure 2: Comparison of friction torque.
high-speed (HS) version of this system allows
achievement of circumferential speeds as
high as 8 m/s, confirmed by field testing.
Robotic applications demand high speed,
with faster acceleration and deceleration,
compared with standard industry gearbox-
es. They encompass a compact space with
sophisticated load spectrums. Internal con-
tamination is of heightened concern as well.
For all these reasons, it is expected that the
MSS 1-HS will have its first application in
the drives of industrial robots. This new
sealing solution also is important to auto-
mation, with a focus on high-reliability
and a requirement to be maintenance-free.
Additionally, because of its robustness, the
solution is suited for other types of drives
that are vertically positioned — with the
motor positioned on the downside, prevent-
ing internal contamination and enhancing
service life across a variety of industries.
Freudenberg produces 5 billion seals per
year — more than 20 million per day — for
virtually every industry from automotive
to aerospace to agriculture, construction
and heavy equipment, to energy, and food Figure 3: Comparison of power loss.

54     gearsolutions.com
Fig. 4:

and beverage. The development of materials and technologies that

address the unique needs of one industry’s challenges are constantly
leveraged to offer innovative new solutions to other industries. In
that spirit, the MSS 1 has an ever-expanding array of applications.
It can be used in the gearboxes of an agricultural tractor or a piece
of construction equipment or in industry for conveyor belts; as well
as in the most precise industrial robotic applications.
Today’s global manufacturing environment requires optimiza-
tion of every component and every process. Global design and the
need for economies of scale are driving standardization. Nonetheless,
regional customization is often necessary to meet various regulatory
requirements. In the United States, there is a regulatory emphasis
on environmental protection and energy efficiency that drives the
need for these innovative custom solutions.
In that respect, this new sealing solution offers manufacturers
twofold value. The custom solution delivers immediate improve-
ment in operational efficiency, including immediate energy savings
and the resultant emissions reduction. Additionally, it delivers long-
term value in extended component longevity, reduced or eliminated
cost of maintenance, and overall reduced cost of manufacturing.
To the industry, this solution is a game-changing innovation in
custom sealing technology. It can be further adapted and customized
to meet demands in specific manufacturing environments, which
will lead to applications and answer demands — some not yet antici-
pated — that will be critical to the manufacturing industry in the
future.  
Figure 4: The performance characteristics of MS 1.

ABOUT THE AUTHORS Marcel Santos and Benjamin Kohl are with Freudenberg Sealing Technologies. For more information, go to www.fst.com.

ARE YOU MAXIMIZING YOUR EXPOSURE?

Connect your company to the gear industry with
JOIN THE GEAR SOLUTIONS a storefront in the Gear Solutions Community.
COMMUNITY Storefronts paint a portrait of your company with
FOR ONLY a 500-word description and include your logo,
$
350
PER YEAR
website link, phone number, email addresses, and
videos. Your social media pages such as Twitter
and Facebook are integrated with live updates,
which may also be re-posted through our social
media feeds.
With a community storefront, your company also
receives a premium listing in the annual Buyer’s
Guide published each November. Premium listings
feature graphic treatments to draw more attention
to your company.

For information on how you can participate in the GearSolutions.com

community storefront, contact chad@gearsolutions.com.
Chad Morrison – associate publisher
800.366.2185 x 202

August 2018     55
COMPANY WENZEL AMERICA
PROFILE

A GLOBAL
COMPANY WITH
A LOCAL FEEL

The SF 87 Shopfloor machine.

(Courtesy: Wenzel America)

56     gearsolutions.com
Wenzel America is an innovative provider of
customized metrology solutions, built on a solid
foundation of German precision engineering and
strong partnerships as a family-owned company.
By GEAR SOLUTIONS STAFF

W
ith thousands of customers around the including automotive, aerospace, energy, construc-
world using Wenzel machines, the compa- tion, defense, transportation, agriculture, and others,
ny is considered a leader in the metrology since just about any part in manufacturing needs to
industry. Its focus is on solving the toughest be measured in some way,” Marks said.
measuring requirements for its customers, wielding
its longtime expertise in German engineering, which DEVELOPING RELATIONSHIPS
dates back to 1968. Parent company Wenzel Präzision Wenzel’s customer philosophy is based on developing
GmbH was founded by Werner Wenzel in Wiesthal, personal relationships and meeting customer needs
Germany, as a provider of testing equipment and preci- as a family-owned business.
sion measuring tools. Wenzel’s development of its first “We have custom solutions for our CMMs and High
3D coordinate measuring machine in 1980 paved the Speed Optical inspection machines; we have close col-
way for its continued success. laborations with our customers, and we have quick
Wenzel Steintechnik GmbH was founded in 2006 response times regarding our service,” Marks said.
in order for Wenzel to have direct control over the “This makes us effective and flexible when it comes
granite that is so imperative in all Wenzel metrology to solving our customers’ problems
machines. What sets Wenzel apart is being a global company
with a local feel.
COMPANY EXPANSION “We are large enough to support customers around
In 2007, the company expanded to Singapore the world, while providing a unique and personal level
and opened another office in Leipzig, Germany. of service,” Marks said. “We always strive for lasting
Additionally, Wenzel America became
its own entity to spearhead sales in
North America. The expansion into the
U.S. was an important milestone for the
company, especially due to the size of
the U.S. metrology market.
Wenzel continued to expand into
South Asia and entered the computer
tomography market in 2008. In 2009,
the Wenzel ScanTec division opened its
doors to provide optical high-speed mea-
surement and digitization solutions.
“The inception of the company in
1968 by Werner Wenzel has had a pro-
found effect, changing the landscape of
what the metrology industry is today,”
said Mariano Marks, product specialist
at Wenzel America. “We are the largest Wenzel’s customer philosophy is based on developing personal relationships and
family-owned company in our industry, meeting customer needs as a family-owned business.
and we strive to compete in all indus-
try sectors with products ranging from CMMs for 3D quality and our customers’ continued success.”
metrology to laser and structured light sensors, opti- Another way he said he sees gear metrology and
cal high-speed scanning, and computed tomography.” inspection evolving is with even bigger gears requir-
Wenzel has 35 employees in its Wixom, Michigan, ing the same types of tighter tolerances that smaller
location, and its headquarters in Wiesthal, Germany, gears do.
employs about 350 employees, with more than 630 Wenzel offers on-site and off-site training for its
worldwide including Europe, Asia, and the Americas entire suite of gear software as well as training for its
and operating in more than 40 countries. other metrology software such as Quartis, OpenDMIS,
“We serve almost all manufacturing industries and PointMaster.
August 2018     57
Wenzel’s granite being hand-lapped for maximum intrinsic accuracy.

CERTIFICATION
The company is also AUKOM certified to
provide an up-to-date, comparable, control-
lable, comprehensive, and certifiable train-
ing program regarding industrial produc-
tion metrology, particularly in the area of
coordinate metrology.
“It is a program for metrologists, produc-
tion engineers, design engineers, and even
managers — really, anybody in the field of
metrology who wants to enhance their skill-
set through our one-week training courses,”
Marks said. “It helps reduce costs, minimize
waste, and make effective decisions. AUKOM
is increasingly being recognized globally
with companies that aim to maintain a high
level of metrology practices and knowledge.”
For the company’s future initiatives, it
foresees refining and developing its product
offerings to reflect the needs of the market,
according to Marks.
“For example, we exhibited our new
exaCT U computed tomography machine at
the Control show in Stuttgart, Germany,”
he said. “We also want to enhance the user
experience through our software and tech-
nology, for example, by providing software
modules updated with the latest metrology The Core’s sensor can capture a blade’s geometry with thousands of points in a little amount of time.
standards and intuitive user interfaces.”
Wenzel America is ISO/IEC 17025 accred-
ited through ANAB for the calibration of
inspection equipment. The company will be
MORE INFO www.wenzelamerica.com
at IMTS in booth #135622. 
58     gearsolutions.com
 High Tech is our Business

ALD is a leader in vacuum

process technology and Heat
treatment services.

LEADERS IN THE
CONTROL OF DISTORTION
ALD Thermal Treatment, Inc.
+ Low Pressure Carburizing
+ High pressure gas quenching
+ Gas Nitriding
+ Ferritic Nitro-Carburizing
+ Plasma Carburizing
+ Normalizing
+ Hardening
+ Annealing
+ Brazing
+ Cryogenic Treatments
+ Engineering services and
process development
+ Prototype and trials

Global Service Centers

Enrique Lopez – Sales and Marketing
 Limbach-Oberfrohna Email: sales@aldtt.net
Germany Phone +1 (810) 357-0685
 Port Huron, Michigan
ALD Thermal Treatment, Inc.
USA 2656 24th Street
 Ramos Arizpe, Coahuila Port Huron, MI 48060, USA
Mexico

www.aldtt.net

ALD is a subsidiary of AMG Advanced Metallurgical Group N.V.

August 2018     59
 PRODUCT
SHOWCASE NEW PRODUCTS, TRENDS, SERVICES & DEVELOPMENTS

Dutch engineering
from Bega Special
Tools available in U.S.
Bega Special Tools will present the latest
tools for easy and safe installation and
removal of bearings and other transmis-
sion parts at IMTS 2018 in Chicago, at Booth
12144.
The Betex MF Quick-Heater, a multifunc-
tional frequency induction heater for both
mounting and dismounting bearings and
other machine parts is the latest heater
design. There is no limit to size or shape of
the components as the heater works with
fixed or flexible hose-type inductors. The
MF Quick-Heater generator is compact and
easy to move. It is clean and operates very
quietly. Heating cycles can be stored on a
computer, and generators can be linked to
work together. This method saves valuable
time as it can be deployed very rapidly, needs The Betex MF Quick-Heater 3.0. (Courtesy: Bega Special Tools)
fewer actions, and can heat faster than con-
ventional methods. year, we will have a bigger booth to demon-
Besides the Betex MF Quick-Heater, the strate how our tools differ from other stan-
offering includes heaters, hydraulic pullers, dard tools.”
pumps, cylinders, and jacks. Betex heaters Bega Special Tools, headquartered in The
for mounting are designed for industrial use. Netherlands, manufactures and sells spe-
They have a robust design, are ergonomic, cial tools, induction heaters, and hydraulic
and maintenance-free. Betex hydraulic cylinders to more than 60 countries. Bega’s
industrial pullers have a capacity from four products are used in production and main-
to 150 tons. They are known for their unique tenance departments of MRO and OEM com-
design with integrated pump and cylinder, panies within a variety of industries, includ-
self-centering arms and jaw construction, ing special solutions for the railway, wind
and providing safety and user convenience. energy, mining, and steel industries.
Betex industrial hydraulic equipment such
as pumps, cylinders, and jacks up to 700 bar MORE INFO www.begaspecialtools.com
are compatible with major international
brands.
“Products of our Betex brand are used Big Kaiser’s tightening
fixture ensures
all over the world by engineers involved in
maintenance and production,” said Richard
Imbro, Bega’s national sales manager for the
U.S. “All tools and methods have one thing in
precision
common: They are designed to make the job Big Kaiser presents the Torque Fit, a tight-
easier, faster, and – above all – safer. ening fixture for collet chucks with an inte-
“If you are involved in machine mainte- grated torque measuring system. This device
nance, then you know the importance of hav- makes it easy to ensure that a collet chuck is
ing the right tools for the right job,” Imbro correctly tightened.
said. “Make sure you plan your visit to our Proper tightening is an important first
IMTS booth to see and get a feel of our spe- step of high-precision cutting. Big Kaiser’s
cial tools for mounting and dismounting Torque Fit notifies the user of a correctly set The Torque Fit by Big Kaiser will be showcased at
bearings and other transmission parts. This torque value via an audible buzzer. If over- IMTS 2018, Booth 43610. (Courtesy: Big Kaiser)

60     gearsolutions.com
tightening occurs, the error LED light will
flash.
The Torque Fit was developed to replace
multiple torque wrenches and has adapt-
ers available for all common machine tool
interfaces such as CAT, BT, SK, HSK, and BIG
CAPTO, making it an economical invest-
ment. For maximum convenience, torque
values for all Big Kaiser-made collet chucks
are preset. The operator can, however, use a
generic setting to tighten any collet chuck
with a torque value up to 80 Nm (60 ft-lbs).
Big Kaiser, a global leader in premium
high-precision tooling systems and solu-
tions for the metalworking industries, will
be showcasing the Torque Fit at IMTS 2018
Booth 431610, along with several other inno-
vative products.

MORE INFO www.bigkaiser.com

EMAG to present
variety of new
machines at IMTS
EMAG, a worldwide leader in manufacturing
systems for precision metal components, will
debut four machines to the North American
The EMAG HLC 150 H will debut to the North American market at IMTS Booth 339436.
market at IMTS this year, while showcasing
several others. IMTS is September 10-15, 2018,
in Chicago. EMAG will be in the South Hall
Booth 339436.
New to North America are the VLC 200
GT, HLC 150 H, VLC 50 TWIN, and the CI
400. Other machines featured will include
the VL 3 DUO, VT 4, and the Eldec MIND-M
250. In addition, EMAG will have a display
of its industry 4.0 options. Details on the
machines to be displayed are:
The VLC 200 GT turning/grinding
machine for chucked components is espe-
cially designed for precise, process-reliable,

sales@nordex.com | eng@nordex.com | (203) 775-4877

ISO Certified / ITAR Registered / Trace Certified

Nordex.com
August 2018     61
PRODUCT
SHOWCASE

and cost-effective manufacturing in medi-
um- and large-scale production. Typical
workpieces machined on the VLC 200 GT
include gears, sprockets, sliding sleeves, and
parts for CVT gears. The machine combines
the benefits of vertical hard turning with
those of grinding on a single machine and
in a single clamping operation.
The HLC 150 H offers high-performance
technology and the capability to produce a
wide variety of workpieces, from gear shafts
and armature, to pinions and planetary
gears, with a maximum length of up to 500
millimeters (20 inches).
The VLC 50 TWIN offers simultaneous
machining for highly productive manu-
facturing. Featuring two main spindles in
one machining area, it can simultaneously
machine two identical workpieces, allowing
for a significant increase in output quanti-
ties and a lower cost/piece. The diameter and
length of both components can be corrected
independently of one another. The machine
also has a direct position measuring system
and a linear motor in the X-axis to ensure
the highest machining quality and maxi-
mum productivity.
The CI 400 is a well-suited solution for

the electro-chemical machining of rotor car-
riers. Rotor carriers are components of elec-
tric motor housings for hybrid vehicles and
are being produced in increasing numbers.
Electro-chemical machining offers decisive
benefits for the production of these parts.
The VL 3 DUO turning machines com-

bine the technological developments of
recent years, including pick-up automation
and the TrackMotion automation system,
to the modular basic design of the CNC
machine. This creates an extremely efficient
production system offering maximum pro-

The
ductivity with minimal space requirements.
Like every EMAG modular turning machine,
the VL 3 DUO multi-spindle machines are

Power
equipped with their own parts storage unit
and a pick-up spindle for each work area.

of One2
VT 4 lathes offer maximum efficiency

in shaft production. They feature short cycle
times, high precision, and safe processing,
among other attributes of shaft machining
Your Objective: on the running machines of the VT series.
One face in perfect alignment with another. For infinity. These lathes literally stand the classical hori-
zontal machining process on its head.
The Eldec MIND-M 250 is a compact

hardening system for basic heat treatment of
checked parts and shafts, provided by EMAG
eldec. Heat-treatment tasks are performed
at 30kW in high-frequency applications and
100kW in medium frequency.
No problems. No distress. No delays.
MORE INFO www.emag.com
That’s the same objective you have for choosing your gear producer.
Circle Gear’s objective is to engage with every customer’s objectives.

 One to 1000 gears Emuge to demonstrate

 Customer designed or reverse engineered
 Gearbox repair, rebuild or redesign
 OEM or end-users
 ISO 9001:2015 Certified
1501 S. 55th Court, Cicero, IL 60804
(800) 637-9335
(708) 652-1000 / Fax: (708) 652-1100
sales@circlegear.com
www.circlegear.com
Spiral and Straight Bevel Gears (Cut, Ground or Lapped) • Spur Gears • Helical Gears •
Long Shafts • Herringbone Gears • Involute and Straight Sided Splines • Internal Gears •
Worm and Worm Gears • Racks • Sprockets • ISO Certified
Partnering with QualityReducer to provide
Gearbox repair, rebuilding and reverse-engineering.
Circle-Gear-ad-2017-Gear-Solutions-4.75x7.25.indd 1
62     gearsolutions.com
new Punch Tap
technology at IMTS
Emuge Punch Tap technology, also called
helical cold-forming of threads, constitutes
the fourth method for the production of
internal threads besides tapping, cold-form-
ing of threads, and thread milling. This
patented method was developed in coopera-
tion between Audi AG and Emuge and is now
available in North America.
The Punch Tap was developed to signifi-
cantly reduce the cycle time associated with
threading aluminum castings. Emuge not
only created a new type of tool for helical
thread-forming but also a completely new
1/17/17 1:13 PM
technology for machining threads. Thanks
to entirely new kinematics with a signifi-
cantly shorter tool path, the new process pro-
 only to clamp workpieces but also to clamp
tools. By applying an axial force, the clamp-
ing sleeves move in the direction of the force
and expand radially. This eliminates the
clearance between clamping sleeve and body,
and between clamping sleeve and workpiece.
System SP achieves concentricity of < 0.002
mm (corresponding to < 0.0001 inch).
For workpieces that have a short clamp-
ing base or for diameters with a very large
tolerance, System SZ is the best choice. By
applying an axial force, a slitted collet is radi-
ally expanded by a cone. Simultaneously an
axial movement occurs, clamping the work-
piece.
When the eccentricity between pitch
circle and seating bore is very small, dia-
phragm clamping System SM is ideal. It
allows clamping of the gear wheel at the
pitch circle for machining the seating bore.
The gear wheel is clamped in both axial and
radial directions.
MORE INFO www.emuge.com

Reliability begins
Emuge’s Punch Tap features a revolutionary design
for helical thread-forming. See it at IMTS booth
431536. (Courtesy: Emuge)
with a cup of begins
Reliability coffee.
with a cup of coffee.
Relationships are built by taking the time to sit down
duces internal threads at a reduced energy with you, & discovering what keeps you awake at night.
consumption and is faster by approximately
75 percent compared to the conventional C olonial isn’t typical in the CUTTING TOOL INDUSTRY-
threading technology. See this new technol-
ogy in action at IMTS 2018, Booth 431536. Reliability begins Relationships
our main focus isare
with
perfectyou,
built bycustomer
to establish
& discovering
fit with
taking relationships
our decades ofwhat
the time tothat
servicekeeps
sit down
youcutting
providing
are a
awaketools
at night.
to international companies looking for
MORE INFO www.emuge.com with a cup
C of coffee. experience
olonial isn’t typical in the and reliability.
CUTTING TOOL INDUSTRY-
our main focus is to establish customer relationships that are a
perfect fit with our decades of service providing cutting tools
Relationships are built by to taking the time
international to sit down
companies looking for
Emuge to display full with you, & discovering what experience and awake
keeps you reliability.
at night.
C
range of workholding olonial isn’t typical in the CUTTING TOOL INDUSTRY-
our main focus is to establish customer relationships that are a
perfect fit with our decades of service providing cutting tools
solutions at IMTS to international companies looking for
experience and reliability.
At IMTS this year, Emuge Corp. will showcase
its comprehensive line of clamping solutions
at Booth 431536. Emuge’s workholding divi-
sion specializes in providing highly accurate,
almost maintenance-free customized solu-
tions for applications from low-volume job
shops to high-volume automotive produc-
tion environments.
“Our workholding group stays close to
our customers to learn about their unique
challenges and production environments.
The solutions we provide delivers the highest quality in the
Doing so helps us develop the best solutions
world at a reliable Lowest Cost Per Piece, GUARANTEED!
TheWhat
An industry first.
for their applications,” said David Jones, pre- solutions
do youwe provide
take in yourdelivers
coffee?
cision workholding manager at Emuge Corp. The solutions we provide delivers the highest quality in the
worldthe
at ahighest qualityCost
reliable Lowest in the
Per world
Piece, GUARANTEED!
The precision workholding lineup on dis-
play will include:
An industry
atworld first.
a reliable
The solutions Lowest Cost Per
What
we do you
provide take
delivers Piece,
intheyour coffee?
highest quality in the
at a reliable Lowest Cost Per Piece, GUARANTEED!
With its expanding-bush design, GUARANTEED!
An industry first. What Ando industry first.coffee?
you take in your What do you take in your coffee?
Emuge’s System SG is used in many machin-
ing operations such as hobbing, shaping, and
shaving for gear production, as well as mill-
ing and inspection. The System SG’s large
surface area contact with the workpiece United States • Canada • Mexico • 1-866-611-5119 • info@actsadvantage.com• www.actsadvantage.com
provides a clamping solution which is very
UnitedUnited
StatesStates
• Canada • Mexico • 1-866-611-5119 • info@actsadvantage.com• www.actsadvantage.com
• Canada • Mexico • 1-866-611-5119 • info@actsadvantage.com• www.actsadvantage.com
rigid, accurate, and repeatable.
The high precision System SP is used not
August 2018     63
PRODUCT
SHOWCASE

Supfina expands of a wide variety of gears, among numerous

other parts. At IMTS, Supfina will be in the
line of fine-grinding North Building, Booth 236949.

machines From aluminum to steel, soft plastics to

Supfina Machine Company, Inc. has expand-
ed its line of fine-grinding machines to
include the Spiro F5 and the Spiro F12, each
of which make its North American debut at
IMTS 2018 in Chicago. Along with the Spiro
F7, the three machines provide customized
solutions for the “batch mode” processing
hard ceramics – no matter the material, the
Spiro series can achieve highly precise plane
parallelism (≤ 1.0 µm). Such precision is cru-
cial for gearboxes and other gear applica-
tions. And because gears can be machined
up to 20 times faster than lapping and with
more precision than double-disk grinding,
costs per unit are reduced substantially.

Parts to be finished are loosely placed in “carriers”

that pins rotate in an orbiting manner. Machining
takes place between two grinding wheels (diamond or
CBN). (Courtesy: Supfina)

Depending on the gear’s material, dimen-

sions, starting surface finish, and removal

GEARING AHEAD TO MEET

requirements, a single Spiro can fine-grind
several thousand per hour.

INDUSTRY'S DEMAND FOR

For plane-parallel fine grinding on both
sides, gears are loosely placed in carriers
that have teeth on the outside diameter. An

PRECISION
inner pin ring rotates the carriers as they
shift on a stationary outer pin ring in an
orbiting manner. Machining takes place

SERVING:
between two rotating grinding wheels
(lower and upper). The optimal machining
Aircraft • Aerospace • Actuation force is applied by the upper wheel.
The smaller F5 can process gears with
Instrumentation • Optic diameters of 4 mm to 150 mm and thick-
Robotics • Radar • Medical nesses of 0.3 mm to 50 mm, while the larger
Marine • Defense • Experimental F12 can accommodate gears with diameters
of 6 mm to 420 mm and thicknesses of 1
Prototype • Production
mm to 100 mm. (The midsize F7 is suitable
Hi-Performance Automotive for gears with diameters and thicknesses
of 5 mm to 220 mm and 0.6 mm to 80 mm,

CNC Thread Grinding respectively.)

“We’re bringing to fine grinding the same

PRECISION GEAR PRODUCTS

process know-how — decades of research and
development — that we’ve mastered in the
field of superfinishing,” said Andrew Corsini,
(up to AGMA Q14) president and chief executive of Supfina’s
Spur Gears, Helical Gears, Worm Gears, Anti-Backlash Gears, North Kingstown, Rhode Island, manufac-
Cluster Gears, Clutch Gears, Face Gears, Planetary Gears, turing facility. (Supfina also has a plant in
Gear Assemblies, Gear Boxes, Bevel Gears, Miter Gears, Wolfach, Germany.) “With the Spiro line we
can offer reliable, economical machines that
Metric Gears, Internal Gears, Idler Gears, Gear Rack & Pinion,
provide all of the best features for the fine-
Worms, Wormshafts, Splines, Spline Shafts, Serrated Shafts. grinding, batch-mode process.”
Regarding maintenance, because the

STD Precision Gear & Instrument, Inc.

Spiro eliminates water from the cooling
process, there’s no chance of contamina-
318 Manley St. • W. Bridgewater, MA 02379 tion — thus drastically cutting costs (the
coolant is also recycled). The machines’
(888) STD-GEAR or (508) 580-0035 sturdy bases keep vibration to a minimum,
greatly reducing tool wear, while their mod-
Fax (888) FAX-4STD or (508) 580-0071
ular, ergonomic design allows quick tooling
E-mail info@stdgear.com • Web site: www.stdgear.com
changes and easy accessibility. For example,
the upper part of the machine swivels com-
64     gearsolutions.com
pletely out of the work area, allowing fast
loading and unloading of parts as well as
easy maintenance.
A high-precision, indirect measuring
system (probe and anvil) guarantees opti-
mal process results that can be duplicated
from batch to batch, thus increasing yield.
That’s because such factors as coolant tem-
perature and abrasive contamination do
not affect the measuring system.
In terms of service, Supfina assigns a
dedicated senior project engineer who
provides not only installation and training
but also ongoing customer support for each
particles that result from grinding, honing,
lapping, eroding, and other metal working
processes. The automatically controlled fil-
ter backwash process is activated only on
demand and separates contaminated and
clean oil 100 percent. Using a combination
of frequency-controlled filter pumps and
on-demand filtration, the resulting energy
consumption is extremely positive and lower
than competing units.
The special high-performance pre-coat
filters ensure that clean oil meeting the
purity class of NAS 7 (3-5 µm) is available
for the grinding process for long periods
of time. Vomat filtration systems are low-
maintenance, compact, and are available
in several sizes ranging from stand-alone
units for single machines to plant-wide
central systems. Their modular concept,
offering a plethora of cooling and disposal
options along with the ability to handle
mixed use of carbide and HSS, allows for
customized systems which will suit every-
body’s needs.

Reliability begins
machine that it sells. By combining all of
these features with quality and reliability,
Supfina is fast becoming the technology
leader for surface-finishing

MORE INFO www.supfina.com

with a cup ofbegins
Reliability coffee.
with a cup of coffee.
Relationships are built by taking the time to sit down with you,
and discovering what keeps you awake at night.
Relationships
C olonialand Reliability begins
are built
isn’t typical in theby takingINDUSTRY-
SPINDLE the time toestablishing
sit down customer
with you,

olonialthe
delivers
with a cup of coffee.
isn’t
discovering
typical
highest
what
in theinSPINDLE
quality
keeps you
the worldINDUSTRY-
awake at night.
relationships that are a perfect fit providing spindle systems to international
Ccompanies looking for experience and reliability. The solutions we provide
at a reliableestablishing
Lowest Costcustomer
Per Piece,
Relationships
relationships
GUARANTEED! that are aare builtfit
perfect byproviding
taking thespindle
time to sit down
systems with you,
to international
companies looking andAnfor
industry
discovering first.
experiencewhat keeps you The
and reliability. awake at night.
solutions we provide
delivers
What dothe take inquality in the world at a reliable Lowest Cost Per Piece,
highest
you
C
GUARANTEED!olonial isn’t typical in the SPINDLE INDUSTRY- establishing customer
relationships An
your coffee? thatindustry first.
are a perfect fit providing spindle systems to international
companies
What do you take looking
in for experience and reliability. The solutions we provide
delivers the highest quality in the world at a reliable Lowest Cost Per Piece,
your coffee?
GUARANTEED! An industry first.
Vomat ultra-fine filtration systems are low- What do you take in
maintenance, compact, and can easily be configured your coffee?
to meet customer needs. (Courtesy: oelheld)

Vomat brings ultra-fine

filtration technology
to IMTS 2018
Only through the use of extremely clean
grinding oils can high-quality cutting tools
be ground economically and reliably against
increasingly tight tolerance requirements.
To meet these requirements, filtration sys-
tem manufacturer Vomat provides compact,
powerful, and energy-efficient solutions for
the metal processing industry. During IMTS EXPERIENCED • RELIABLE • INTERNATIONAL
2018, Vomat will be showing examples for
EXPERIENCED • RELIABLE • INTERNATIONAL
individually tailored concepts for the filtra- United States • Canada • Mexico • 1-866-611-5119 • info@colonialtool.com • www.colonialtool.com
EXPERIENCED • RELIABLE • INTERNATIONAL
tion of cooling lubricants at Booth N-237475. United States • Canada • Mexico • 1-866-611-5119 • info@colonialtool.com • www.colonialtool.com
Vomat will also present its filtration units at
AMB 2018. Vomat filtration systems are ideal
United States • Canada • Mexico • 1-866-611-5119 • info@colonialtool.com • www.colonialtool.com
for filtering oils and removing the ultra-fine
August 2018     65
 PRODUCT
SHOWCASE

Besides the compact stand-alone units of offered in the market place.

the FA series (70- to 1,200-liter flow rate/min-
ute), the new Vomat vacuum belt filter UBF
will be a focus of the fair. With a filtration
fineness of 3 to 25 µm, it is ideally suited for
filtering oils and emulsions contaminated
with steel, HSS, binders, and grinding wheel
particles.
According to Vomat, the UBF filter
requires about 70 percent less space while
delivering 100 percent of the performance
when compared to conventional systems
Vomat’s sales manager Steffen Strobel
said, “Efficient, space- and energy-saving
filtration is becoming increasingly impor-
tant. Choosing the right filtration system
will have a positive impact on production
costs. Thanks to Vomat technology, a lot of
money can be saved in production.”
oelheld is the exclusive Vomat distributor
in North America.
MORE INFO www.oelheld.com

Exsys planetary gearbox provides excellent energy

Sourcing Made Simple

efficiency, minimal heat generation. (Courtesy: Exsys
Tool, Inc.)

Exsys offers range

of precision planetary
gearbox solutions
Trusted Gear Blank Exsys Tool, Inc. has expanded its line of
Eppinger high-precision industrial gearbox-

Supplier Since 1950 Trusted Gear Blank

es to include planetary-type gearboxes. The
planetary range provides excellent energy

Supplier Since 19
efficiency, minimal heat generation and
extremely smooth motion for a wide variety
of applications and industries.
Consistent Quality Standard planetary gearboxes are avail-
ableConsistent
in PE (planetaryQuality
eco) and PP (planetary
precision) styles for applications that require
Broad Capability & Capacity lowBroad
backlash,Capability
high efficiency,& Capacity
shock resis-
tance, and a high-torque-to-weight ratio.
Exceptional People WithExceptional
a modular design People that combines
Trusted Gear Blank ground gears and precision gear compo-
On-time Delivery
On-time Delivery Supplier Since 1950 nents, these gearboxes ensure performance
efficiency and maximum uptime. They also
use less energy and easily mount to a variety
Consistent Quality ISO 9001 and TS 16949 registered. Presses up to
Broad Capability & Capacity
of motors through a flexible flange system.
8800T Theandpresent
volumes upofto 750K/year. Supported b
SO 9001 and TS 16949 registered. Presses up to Exceptional People
range planetary gearboxes
On-time Delivery in-house heat treat and an ISO 17025 metallurgic
comprises five sizes, with each size offered
800T and volumes up to 750K/year. Supported by as a single-, dual-, or triple-stage design. Each
gearbox variant is also available as a preci-
n-house heat treat and an ISO 17025 metallurgical lab.
9001 and TS 16949
ISO 9001
8800T
4000T and volumes
16949 registered.
volumesup uptoto750K/year.
Pressesupuptoto
registered. Presses
750K/year.Supported
Supportedbyby sion design with reduced backlash. The wide
in-house
in-househeat
heattreat
treatand
andananISOISO17025
17025metallurgical
metallurgicallab.
lab. assortment of sizes and designs allows users
to achieve overall transmission ratios from i
= 3:1 to i = 512:1 in a variety of applications.
Servo planetary gearboxes in PT-style are
also available for easy installation of all com-

walkerforge.com walkerforge.com
| 414.223.2000 |
414.223.2000
mon servo motors with all sizes of the gear-
boxes. PT-style gearboxes feature a unique
design by which all ring gears, planet gears,
and sun pinions are case hardened and
ground to guaranteed high stiffness, reliable
transmission, and allow precise positioning
tasks.

MORE INFO www.exsys-tool.com

66     gearsolutions.com
 linked manufacturing solution. The inter-
linking option is made easy to implement
by the consistent transfer height between
the automation systems of individual
machines. In addition, the separate energy
container allows the use of the new EMAG
TrackMotion automation system specially
developed for modular machines.
The vertical VL 4 H hobbing machine can
be configured for a wide range of applica-
tions. The high-performance drives used in
the working spindle and in the hob enable
high speeds and torques, ensuring fast,
precise, and cost-optimized gear produc-
tion. The machine allows dry gear hobbing
of workpieces with diameters of up to 200
mm and module 4. The optionally available
measuring system for part alignment can
be expanded by adding a sensor system for
positioning. It not only allows adjustments
to be made to the machining operations at
any time, it also permits seamless documen-
tation for production quality assurance.
The machining area of the VL 4 H is

BROACH CUTTING TOOLS

HOW ‘BOUT
I RIP YOU A NEW
The vertical VL 4 H is designed for wheel-shaped ONE MORON!
workpieces with diameters up to 200 mm and module DON’T TALK
TO ME ABOUT
4. (Courtesy: EMAG) TOLERANCES,
I’VE HAD IT
WITH YOU!!!

EMAG’s modular VL 4 H I DON’T CARE

designed with whole WHAT YOUR SUPPLIER

PROBLEMS ARE, I WANT IT
AS PROMISED.PERIOD!

process in mind HELLO COLONIAL -

GUYS YOU GOTTA
I HAVEN’T HAD
A FAMILY DINNER
IN WEEKS!
HELP ME OUT HERE,
EMAG, a company with many years of suc- I’M IN A HECK OF ...AND THE
A JAM LOWEST COST
cess in the field of gear cutting, has demon- WOW! PER PIECE..
ON TIME & GUARANTEED!
strated its capabilities in a multitude of proj- ON BUDGET.

ects for a broad clientele. Satisfying the most

demanding requirements is second nature
for the company’s gear-cutting experts, who
meet such requirements with the necessary
expertise and first-rate technology.
Technology such as that is used in the
new modular VL 4 H hobbing machine,
which is the experts’ answer to the
demands of high-volume manufacturing. Colonial gives you the
EMAG’s modular machines belong to a opportunity to relax COLONIAL DOESN’T KNOW IT BUT
successful machine series that combines
the different technologies of the EMAG
& enjoy your coffee ... THEY SAVED MY MARRIAGE AND MY
CUSTOMER. WITH TODAY’S TIGHT
MARGINS YOU SIMPLY CAN’T AFFORD
Group in a standardized machine base. TO TAKES CHANCES WITH QUALITY.
Whether for turning, grinding, induction
hardening, or gear cutting, the proven
EMAG pick-up principle ensures highly
automated, efficient production. The pick-
up automation system integrated into each
modular machine features a parts storage
unit for blanks and finished parts, from
which the machine is automatically loaded. Start your day with confidence.
This results in very short chip-to-chip times Have your coffee your way!
of only a few seconds. The vertical construc-
tion of the machine not only guarantees an
ideal chip flow but also prevents the forma-
tion of chip clusters, thus contributing to
a consistently high quality of production. EXPERIENCED • RELIABLE • INTERNATIONAL
The compact vertical design of the United States • Canada • Mexico
machines makes them very attractive 1-866-611-5119 • info@colonialtool.com • www.colonialtool.com
both as single units and as part of an inter-
August 2018     67
PRODUCT
SHOWCASE
Wind Resource & Project Assessment
September 11 – 12 | Austin, TX
www.windpower.org/wra
perfectly accessible through the large
front door, allowing rapid set-up times
clamping operation. To do so, the chamfer
cut tool is mounted on the hob arbor of the
tested this machining combination in the
manufacture of gears. The wheel-shaped
and creating an ergonomic work environ- cutter in addition to the hob. The chamfer workpieces have hardly any interfering
ment for the operator. The combination cut method, developed by Fette, is ideal for contours, so that chamfering with cham-
of powerful drives, a working spindle that precise and low-cost chamfering processes. fer-cut is possible. The machining combina-

Wind Energy Finance & Investment

can be controlled with absolute precision,
tool clamping, and the generously dimen-
sioned machining area allows various dif-
“As this method does not produce any sec-
ondary burr and does not warp the mate-
rial, it is especially suitable for gear teeth
tion of hobbing and chamfering in a single
clamping operation on one machine is of
course a very cost-effective solution for the

Conference – East
ferent gear cutting methods to be used on
the machine. For instance, the chamfer cut
that are honed after hardening,” said Peter
Loetzner, president & CEO of EMAG L.L.C.
user, as two manufacturing processes can
be performed at the same time with just

October 1 – 2 | New York, NY

method can be used to chamfer the work- The workpiece does have to have a suit- one machine, and the workpiece handling
pieces directly after hobbing, with a single able shape, however. “We have successfully between the processing steps is also elimi-
nated. That lets you reduce your floor to

www.awea.org/financeeast floor times and get workpieces to the next

production step faster,” Loetzner said.
The new VL 4 H from EMAG offers users
MAKE PLANS TO ATTEND a multitude of possibilities. As shown in
TOP-RATED CONFERENCES IN 2018 the example, it can be used as a standalone

Wind Energy Finance & Investment machine for gear cutting, or for combined
hobbing/chamfering, or as part of a pro-
duction line, which is relatively easy to

Conference – West do thanks to the advantages of EMAG’s

modular machines. In all cases, the user

October 5 | San Francisco, CA

benefits from the many possibilities that
the machine offers.

www.awea.org/financewestMORE INFO
Wind Resource & Project Assessment
www.emag.com

Conference
All Metals & Forge
September 11 – 12 | Austin, TX
www.windpower.org/wra
Group promotes cost,
Offshore WINDPOWER
Wind Energy Finance & Investment
Conference – East
Conference
quality benefits
&
October 16 – 17 | Washington, DC
October 1 – 2 | New York, NY
www.awea.org/financeeast
All Metals & Forge Group manufactures high

www.offshorewindexpo.org
Wind Energy Finance & Investment quality seamless rolled rings with excellent
Conference – West tensile and yield properties for gear, bear-
October 5 | San Francisco, CA ing, and heavy machinery applications. It
www.awea.org/financewest
can produce forged rings in diameters up
Offshore WINDPOWER Conference & Exhibition to 108 inches for steel alloys and up to 80
October 16 – 17 | Washington, DC inches for other metals, with wall thickness

Wind Energy Fall Symposium

www.offshorewindexpo.org
ranging from 2 inches and up. All parts are
Wind Energy Fall Symposium rough machined and 100 percent UT tested

November 13 – 15 | Colorado Springs, CO

November 13 – 15 | Colorado Springs, CO (ASTM388).
www.awea.org/symposium
Other forged shaft shapes produced

www.awea.org/symposium
include flanged shafts, round bars, spindles,
and hubs.
All Metals offers these high-quality
forged shafts in ferrous and non-ferrous
metals including carbon steel, alloy steel,
stainless steel, titanium, nickel, aluminum,
www.awea.org
and tool steel.
All Metals & Forge Group, an ISO reg-
istered forging manufacturer, has a vast
inventory (300 alloys and grades) on the
floor which will aid customers in the quick-
est deliveries, high quality, and extremely
competitive products.  

MORE INFO www.steelforge.com

68     gearsolutions.com
August 2018     69
  

MARKET KORO for Quality

 
 

PLACE
Hob Sharpening Service
 Quick Turnaround 2 Day Service  
 Spur Shaper Cutter Sharpening
 HSS & Carbide Hob with center hole  
and straight flutes
Contact Gear Solutions  Thin Film Coatings  
at 800-366-2185 to  Length up to 7 inches

feature your business  

 Diameter up
in the Marketplace! to 5 Inches
 
 Precise rake
and spacing guaranteed
to AGMA standards  
 RUSH SERVICE AVAILABLE
Koro Sharpening Service
9530 85th Ave North  
Maple Grove, MN 55369
763-425-5247
info@koroind.com  

FASTER
Atmosphere
VL 3 DUO
Refractory Relines   MULTI-SPINDLE TURNING
MACHINE

  MASTERS
Get hardened and precision ground
PRODUCTIVE PRECISE COMPACT

  master gears in as little as two to three

weeks from receipt of order, thanks
to the complete machining resources
available on-site at Forest City Gear.

If your atmosphere furnace is

in need of a refractory reline,
let Ipsen’s experienced For more information visit:
atmosphere team help you www.forestcitygear.com
restore your furnace back to its
264 sq ft
original condition. FOOTPRINT

go.IpsenUSA.com/Retrofits www.emag.com

see you there! Performance · Custom gear racks in AMERICAN and

METRIC standards, STRAIGHT and
Dependability HELICAL, VARIOUS materials, FINE and
COARSE pitch (254 D.P. – 0.5 D.P.; 0.10
Module – 50 Module); hard-cut (up to
Value 60 Rc) and soft-cut (up to 40 Rc); 32”
face width; Up to 82” lengths – longer
lengths through resetting
· Custom gears in AMERICAN and
METRIC standards (3 D.P. – 72 D.P., 10”
Diameter)
· Precision Quality up to AGMA 12
· Prototype & Production quantities
· Breakdown Service Available
· Reverse Engineering
· Unique Tooth Configurations
· Heat Treating
· Complete CNC Machining

North, level 3
Booth #237024 1.866.HOB.TOOL
w w w . h o b s o u r c e . c o m

70     gearsolutions.com
082018_KappAd_IMTS_NinthPage_GS.indd 1 7/20/2018 3:19:58 PM
ADVERTISER UNITE-A-MATIC
TM

INDEX TRUE DIMENSION GEAR INSPECTION

CONTENTS PAGE NO.

Advent Tool & Manufacturing............................................................ 41
ALD Thermal Treatment Inc.............................................................. 59
All Metals & Forge Group.................................................................. 13 OD / ID INSPECTION  DATA COLLECTION  CUSTOM TOOLING  MITUTOYO DISTRIBUTOR
American Precision Gear Co.............................................................. 71
AWEA (American Wind Energy Association)........................................ 68 CUSTOM FIXTURES
& GAUGES
AVAILABLE
Circle Gear & Machine Co Inc........................................................... 62
Colonial Tool Group..............................................................63, 65, 67
Design2Part Shows.......................................................................... 61
Drewco........................................................................................... IFC
ECM-USA........................................................................................ 11
EMAG......................................................................................... 9, 70
Engineered Tools Corporation............................................................ 20 1973 45th
AN NI VE RSARY
2018

Forest City Gear............................................................................... 70

Gleason............................................................................................. 2
Grieve............................................................................................. 14
Hobsource Inc........................................................................... 14, 70 www.unite-a-matic.com
IMTS............................................................................................... 69
Innovative Rack & Gear.............................................................. 47, 70
Ipsen......................................................................................... 22, 70
KAPP Technologies.........................................................27, 50, 51, 70
KISSsoft AG/Gleason........................................................................ 16
Koro Sharpening Service................................................................... 70
WWW.AMGEAR.COM
Lawler Gear Corporation.................................................................... 47
Leistritz........................................................................................... 10
Liebherr........................................................................................... 31
Lucifer Furnaces.............................................................................. 70
AEROSPACE/DEFENSE
Machinists Inc................................................................................. 17
McInnes Rolled Rings....................................................................... 18
Mitsubishi Heavy Industries America Inc............................................BC
New England Gear.............................................................................. 7
NORDEX.......................................................................................... 61 CONTROLS
Penta Gear Metrology LLC................................................................ 21
Piselli Enterprises............................................................................ 39
Proto Manufacturing Ltd................................................................... 12
Reishauer........................................................................................ 15
Russell Holbrook & Henderson Inc.................................................... 16
MEDICAL DEVICES
Solar Atmospheres..........................................................................IBC
Southern Gear & Machine................................................................. 19 CUSTOM PRECISION GEARS
ISO2015, AS9100, DDTC
STD Precision Gear & Instruments Inc............................................... 64
The Broach Masters Inc...................................................................... 4 SALES@AMGEAR.COM
FOSTER CITY, CA
Toolink Engineering Inc...................................................................... 1
800-554-3150
United Tool Supply........................................................................... 71
Walker Forge.................................................................................... 66

August 2018     71
 Q& A MARC VONDERLAGE
REGIONAL SALES REPRESENTATIVE   
WICKERT
INTERVIEW WITH AN
INDUSTRY INSIDER

“Our equipment allows gear manufacturers to reduce manufacturing

cost and improve quality through automated techniques.”
What does Wickert do for the gear manufacturing
industry?
Wickert is a technical leader in the field of fixture
hardening equipment and pressing systems. Our equip-
ment allows gear manufacturers to reduce manufac-
turing cost and improve quality through automated
techniques. Wickert provides a wide variety of custom
solutions ranging from single to multi-station systems
incorporating many features tailored to address specific
customer needs. Such features include, but are not lim-
ited to:
Fully automatic mold change and storage.
Mold condition monitoring.
Feeding systems for raw material and finished
articles including buffers.
High temperature presses with integrated handling
systems to load and unload the workpieces.
Integrated tempering and after-process cooling.
In-line quality checking.
In-line article cleaning after pressing.
Article “clean blasting.”
Furnace work monitoring systems to optimize
efficiency.
Control integration to customer factory manage-
ment systems.
Remote machine condition monitoring.

What achievements have you recently accomplished

and how does that affect what you do for the
industry?
We recently developed a specialized gripping system
that eliminates damage to the hot articles during trans-
port between stations.

What equipment and services have you added to

better assist customers’ needs?
Our automated solutions incorporate features such as
automatic mold change, mold storage, mold preheating,
and mold monitoring. This makes management of the
many different tools required much more simple and
A Wickert press. (Courtesy: Wickert USA)
efficient in operations.

What are some of Wickert’s proudest moments?
We are proud to supply solutions that help our customers increase
their level of competition within the market by employing our tech-
nically advanced solutions. We can provide these systems worldwide
with great success.
We anticipate automated solutions and integrated systems to become
a standard requirement in the coming years. We embrace Industry
4.0 principles and will continue to develop cutting-edge solutions to
take advantage of new technologies. 

Where do you see Wickert in the next 10 to 20 years and its

MORE INFO www.wickert-usa.com
place in the gear industry?
72     gearsolutions.com
Vacuum Heat Treating Services

...because quality is critical

We know high quality gears and components are
vital to performance. Our leading edge vacuum
technology and expertise provides precise control and
repeatability for consistently superior parts.

• Low Pressure Vacuum Carburizing (LPVC)

• High Pressure Gas Quenching (HPGQ)
• Vacuum Stress Relieving

Advantages
• Uniformity of case depths
• Minimized distortion
• No IGO (Intergranular Oxidation)
• Parts returned clean, free of soot – eliminating
downstream cleaning processes

For more information or a quote,

call 1-855-WE-HEAT-IT
or visit solaratm.com
Nadcap Accredited for Nondestructive Testing at our Hermitage, PA facility only.

Eastern PA California
Western PA South Carolina VACUUM PROCESSING Heat Treating • Brazing • Carburizing • Nitriding
 VISIT US AT
BOOTH
N-237036

Our Technologies, Your Tomorrow

The Power
of Mass
Production

Maximize Production and Profits With

Mitsubishi’s Fast and Accurate ZE Series
Generative Grinding Machines.
When you improve productivity you reduce
costs. With that in mind Mitsubishi developed
its ZE Series of generative gear grinders. It’s
simply more efficient with automatic part
loading and grinding and polishing with one
setup. To learn how you can leverage all the
possibilities of Mass Production, visit
www.mitsubishigearcenter.com
ZE24B
or contact sales at 248-669-6136.
LEGENDARY RELIABILITY