GEAR SOLUTIONS MAGAZINE

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

ISSUE FOCUS
Powder Metal Gears | Chamfering & Deburring

EXTENSIVE
EXTENSIVE APPLICATIONS OF PM GEARS

APPLICATIONS
OF PM GEARS
COMPANY
PROFILE

HORN USA
AUGUST 2023

AUGUST 2023
gearsolutions.com
 We measure
quality in
micrometer
WGT 280 - 1200
www.liebherr.com

Metrology

WGT Gear Measuring Machines

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– Highest accuracy is guaranteed by using granite guides, air bearings, precision

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– Manufacturer neutral GDE interface for data transmission to production machines

Liebherr Gear and Automation Technologies, Inc.

info.lgt@liebherr.com • www.liebherr.com/measuringdevices
 FEATURES

30
EXTENSIVE APPLICATIONS OF PM GEARS
Powder metal gears boast many advantages over more
traditional gear-manufacturing processes.

PRECISION MACHINING WITH ABRASIVE BRUSHES

34 Abrasive brush machining is a cost-effective, time-reducing method that can
complement many workpiece types and solve the problems of many chamfering,
deburring, or finishing challenges.

6 BENEFITS OF AR IN MANUFACTURING
Augmented reality is becoming a growing and useful tool to maintain
a more efficient shop floor during the manufacturing process.
38

COMBINING CUTTING-EDGE TECHNOLOGY,

42 PERFORMANCE, AND RELIABILITY
COMPANY PROFILE Horn USA offers a wide array of cutting tools that can be
used wherever maximum precision is required: From the automotive industry and
aerospace technology to the jewelry industry and medical technology.

2     gearsolutions.com
 ISO9001:2015
SINCE 1994
AS9100D
SINCE 1998

NIST SP 800-171
(COMPLIANCE UNDER
DEVELOPMENT)

Fast Quotes. Fast Delivery.

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for your fast quote today. August 2023     3
 AUGUST 2023 • VOLUME 20, 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.
Fred Young, Forest City Gear leader for over ANCA to premier latest grinding technology
50 years, dies. products at EMO 2023.

19
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

24 MATTER 26 TIPS 28 SEAT
LANE WINKELMANN BRIAN DENGEL D. SCOTT MACKENZIE
& MALCOM MAXEY
WHAT IS A GEAR RACK? NITROGEN-METHANOL ATMOSPHERES –
THE CHEMICALLY ACCELERATED STORAGE AND CONTROL
Gearing 101: A primer on gear racks, what
SUPERFINISHING PROCESS they are and how they’re used. Understanding the physical parameters
Although burnishing is not always of methanol, and the different measuring
necessary for the production of every techniques, will enable precise methanol
gear, an improperly removed conversion (and atmosphere) control.
coating could affect the performance of
the part in some applications.

PRODUCT Q&A
46 SHOWCASE 56
New products, trends, services, and
developments in the gear industry.

RESOURCES
54 MARKETPLACE

55 ADVERTISER INDEX SŁAWOMIR WOŹNIAK

CEO at SECO/WARWICK Group

COVER PHOTO: SHUTTERSTOCK (6) / ILLUSTRATION BY RICK FRENNEA

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:
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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
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“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.

4     gearsolutions.com
Manufacturers of:

and Universal Gear Company

2160
1605 Precision
IndustrialPlace
Drive
Auburn, CA 95603
Phone: (530) 885-1939
Fax: (530) 885-8157

August 2023     5
 FROM THE
EDITOR David C. Cooper
PUBLISHER

EDITORIAL
A look at the many applications Kenneth Carter
of powder metal gears EDITOR

Jennifer Jacobson
W henever a process is used to add material to a product as opposed to subtracting that
material, it stands to reason the process should be more efficient.
At least that’s the concept behind the additive manufacturing aspect of creating powder
ASSOCIATE EDITOR

Joe Crowe
ASSOCIATE EDITOR | SOCIAL MEDIA
metal gears. In creating gears using powder metal alloys, the material is compacted into
a mold using high pressure and then sintered to make solid parts. It’s a well-established
process that has become another tool in designing and manufacturing quality gears for SALES
use in a variety of applications. Dave Gomez
It’s an important process, to be sure. NATIONAL SALES MANAGER
To that end, this month’s Gear Solutions takes a deep dive into powder metal gears and
where and why they may show up.
Kendall DeVane
REGIONAL SALES MANAGER
In our cover article, Robert Gavran with Miba shares his insights on the extensive appli-
cations of powder metal gears and how they can have many advantages over more tradi-
tional gear-manufacturing processes. CIRCULATION
Once gears are first made, they still have to go through many steps before they end up Teresa Cooper
in use. MANAGER
One of those steps may involve chamfering or deburring, which brings us to our next
main article on precision machining with abrasive brushes.
Jamie Willett
ASSISTANT
Abrasive brush machining has been around for decades and can be used in all types of
chamfering, deburring, and finishing of gears.
To help explain more, Adam Mutschler and Eric Mutschler bring their expertise on this DESIGN
often-misunderstood process. Rick Frennea
This issue also includes a look at how augmented reality is helping to assist in the manu- CREATIVE DIRECTOR
facturing process.
In addition to our feature articles, our regular columnists offer up some interesting infor-
Michele Hall
GRAPHIC DESIGNER
mation on a variety of subjects including: In Hot Seat, Scott MacKenzie looks at understand-
ing nitrogen-methanol atmospheres, while in Materials Matter, Lane Winkelmann and
Malcolm Maxey talk about what to expect from your chemically accelerated superfinishing CONTRIBUTING
process. And in Tooth Tips, Brian Dengel asks and answers the question: What is a gear rack? WRITERS
There’s all that and much more in our August issue. I hope you find it as informative REBECCA BRINKLEY
as I did. BRIAN DENGEL
Stay cool, and, as always, thanks for reading! ROBERT GAVRAN
D. SCOTT MACKENZIE
MALCOLM MAXEY
WENDY MLYNAREK
ADAM MUTSCHLER
ERIC MUTSCHLER
LANE WINKELMANN

KENNETH CARTER, editor

editor@gearsolutions.com
(800) 366-2185 x204 Vertical Logo

Coop w
CALL FOR ARTICLES Have a technical paper or other work with an PUBLISHED BY MEDIA SOLUTIONS, INC.
educational angle? Let Gear Solutions publish it. Contact the editor, P. O. Box 1987 • Pelham, AL 35124
(800) 366-2185 • (205) 380-1580 fax
Kenneth Carter, at editor@gearsolutions.com for how you can share
your expertise with our readers. David C. Cooper Teresa Cooper
PRESIDENT OPERATIONS

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Xxxxxxxx 20XX     7
 INDUSTRY
NEWS
Fred Young served as the second generation of Young leadership at the company along with his wife, Wendy, for
more than 50 years. (Courtesy: Forest City Gear)
Fred Young, Forest City
Gear leader for more
than 50 years, dies
Forest City Gear chairman and former presi-
dent Fred Young passed away July 17 with his
family at his side. He was 80. Young served as
the second generation of Young leadership at
the company along with his wife, Wendy, for
more than 50 years.
Young was born April 21, 1943, in Chicago,
Illinois. He earned a B.A. in English litera-
ture from Rockford University in 1965 and
went on to spend a year in the Navy Reserves.
He took over the family business, Forest City
Gear, in 1967. Founded by his parents in
1955, Young took the small “mom and pop”
shop to a global level, leading the company
to manufacture some of the world’s most
difficult gearing for amazing end uses, from
NASA’s Martian rovers and space station to
robotic arms and racing yachts. His middle
daughter, Kika, took the reins of the family
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
business last year.
Young was involved in many community
organizations including his temple, Temple
Beth-el, Trout Unlimited, the American
Gear Manufacturers Association (AGMA),
the board of Rockford University, and many
more. He received dozens of awards over the
years including the Award of Distinction
from Rockford University, the Rockford
Chamber of Commerce Manufacturer of
the Year in 2006, and the 2014 Lifetime
Achievement Award from AGMA. Young
had many hobbies including fly fishing and
hunting, as well as whitewater boating and
kayaking in his younger years.
Young was preceded in death by his
parents, FCG founders Evelyn and Stelter
Young, and his wife, Wendy. He is survived
by his daughters, Appy (Rustin) Mikel, Kika
(Anthony) Risa, Mindy (Ryan Davis) Young;
grandchildren Joey, Kysa, Levi, Addy, AJ,
Nollie, Clementine, Charley, Evie, Wilder,
Stetler; step-grandson, Felix Davis; sister-in-
law Lori (Roger) Brandel; brother-in-law Todd
Nutter; many nieces, nephews, great-nieces,
and great-nephews, his “gear son” Jared
Lyford, and a large circle of treasured friends.
MORE INFO www.forestcitygear.com
Ceratizit adds technical
sales engineer
to Texas-based team
Daniel Campos has joined Ceratizit as a
Texas-based technical sales engineer, bring-
ing deep knowledge of machining and man-
ufacturing to Ceratizit customers. Campos’
career spans more than 22 years in the
machining indus-
try with experience
in vertical, horizon-
tal/live tooling turn-
ing, full milling,
and 3-, 4- and 5-axis
machining. He
also has extensive
experience in CAD/
C A M, Espr itcam,
Mastercam, VeriCut,
Daniel Campos
and SolidWorks.
Ceratizit customers will benefit from
Campos’ broad industrial background that
includes the oil and gas industry, automo-
tive, turbomachinery-centrifugal compres-
sors, and steam turbine sectors. Campos is
versed in 5S and Lean Manufacturing, LINGO
Live for Managers, and has Six Sigma Green
Belt and American Management Association
certificates.
Campos’ approach with cutting tool cus-
tomers is focused on learning their processes
and understanding their unique challenges.
“I do my best work in the field,” Campos
said. “I am dedicated to building relation-
ships with people, understanding where they
are and discovering where they want to be.
Then, I use my two decades of experience to
help get them there.”
MORE INFO www.ceratizit.com
ANCA to premier latest technologies, including ANCA’s unique nano-
meter control, that revolutionizes precision
grinding technology grinding for small and micro tools down to
sion grinding in industries that rely on small
tools, including electronics, telecommunica-
tions, medical devices, aerospace, automo-

products at EMO 2023 0.1mm diameter. This significant technol-

CNC grinding technology pioneer ANCA
will showcase their latest products and
industry-specific grinding and automation
solutions at EMO at Booth F52, Hall 6 in
Hanover, Germany in September. The win-
ner of the Tool of the Year competition will
be announced live September 20 at 4.30 p.m.
(GMT) — and all are welcome to join the
celebrations and witness for themselves the
ultimate range of cutting tools.
“We are excited to bring not one but sev-
eral world premieres to EMO, promising pre-
mium value, higher productivity and extend-
ed capabilities,” said Edmund Boland, ANCA
CNC Machines general manager. “Visitors
ogy breakthrough is already redefining the
standards for tool and component grinding
with the highest levels of accuracy and sur-
face finishes.
New software, hardware, and design fea-
tures significantly improve surface finish,
accuracy, and controlled runout, ensuring
batch consistency from the first ground tool
to the last. These advancements ensure that
the FX7 ULTRA is the go-to solution for preci-
Gears for Missiles
tive, diemold, and general machining.
From blank to a finished high-quality
tool, all on one machine — ANCA’s ultimate
single setup solution for complete machin-
ing of cutting tools will be demonstrated on
the MX7 ULTRA at EMO. Following a legacy
of machine efficiency, this latest solution
combines peel grinding and tool grinding
on the one platform, enhanced with addi-
tional power to extend capability. The MX7
ULTRA’s remarkable spindle power of 26kW

We Never Miss
can see firsthand ANCA’s latest technology
that spans tool precision, integrated manu-
facturing systems, industry focus applica-
tions and optimization across the process
chain.”
“EMO is the global leading manufacturing
technology show, it is where the current mar-
ket trends and innovations are on display,”
said Martin Winterstein, general manager of
ANCA Europe “Our setup in Hanover really Our aerospace and defense
industries are ramping up to
shows hands-on opportunities for tool manu-
meet the challenges of an
facturers, with new application and automa-
uncertain world. Southern
tion solutions tailored to industries’ needs.
Gear’s mission is to meet
I am excited to show visitors our enhanced the growing demand for high
portfolio to include micro tools with the FX precision gears that keep
ULTRA, according to the high demand from missiles on target and aircraft
this growing segment. Experts from ANCA out of harm’s way.
and our partners will be on-site to show
and discuss individual requirements at the Need better gears, delivered
booth.” faster? We’ll hit your quality
In their commitment to creating the and delivery targets with
highest quality product, years of continuous precision accuracy.
refinements at ANCA have made the ULTRA
technology possible. ANCA’s unique verti-
cal integration is key to its success — where
machines, controls, drives, and precision
components are all designed and manufac-
There’s a Better Way.
tured in-house. Successfully introduced to
the industry last year on the MX machine
platform, it boasts the highest accuracy
and quality cutting tools in the world. The
MX7 ULTRA achieves one nanometre axis
resolution, and can maintain better than +/-
0.002mm line form accuracy of any profile
which includes ballnose and corner radius
endmills.
At EMO, visitors will find out how ANCA
Fine, Medium, Coarse Pitch | Spur, Helical | 800.248.5152
spreads the ULTRA advantages to further
Shafts, Sprockets, Worms | Straight Bevel southerngear.com
fields of application, including smaller
batches, regrinding, and tools with small
diameters. HUBzone | Veteran Owned | ISO 9001 | AS9100D | ITAR Compliant
The FX7 ULTRA introduces cutting-edge

August 2023     9
INDUSTRY
NEWS
The ULTRA package with nanometer resolution, design, software and quality features enables manufacturers to
grind tools with very demanding specifications. (Courtesy: ANCA)
can handle demanding tools such as larger
taper ballnose endmills, step drills, and aero-
space components ranging from 0.1 to 25.4
mm. This leads to reduced cycle times and
increased productivity. Short setup times,
optional collet change and proven blanket
grinding processes round out the capabilities.
ANCA has further developed its AIMS sys-
tem for automated tool production. At EMO,
visitors can see examples from the field, with
systems operating completely unattended
over extended period, manufacturing tools.
The AIMS automation package is a modu-
lar and growing system, spanning across
the tool production process. ANCA is set
to include additional operations such as
blank preparation or laser marking in the
automated process. The system’s intelligent
design allows for progressive steps of automa-
tion, including an automated laser marking
station AutoMarkX. The versatile laser mark-
ing station is tailored to meet the needs of
tool manufacturers. It provides reliable and
high-quality marking, ensuring traceability,
identification, and branding of tools, while
eliminating repetitive tasks to free up time
for skilled staff.
The AutoMarkX’s new, retrofittable rotary
workholding system allows for unlimited
index marking around the tool, with auto-
matic Z-axis focus and compatibility with
tool shanks from 3 to 32mm. Moreover, the
AIMS Autoline Basic, the standard interface
for easy loading at the AutoMarkX enables
customers to experience smoother material
transfer between machines.
10     gearsolutions.com
ANCA’s expertise in grinding solutions
extends to blank grinding and integrated
complete machining of gear tools, including
in-process measuring and compensation.
The CPX blank preparation machine will
feature productivity-enhancing features in
Hannover, including automated loading of
tools up to 32mm, a flip station for grind-
ing from both ends, tailstock, and extensive
probing enabling statistic process control.
The machine has been designed to give users
high material removal rates and save time
and money with unattended production.
The rising demand of gear cutting tools
has led ANCA to enhance its product pro-
gram with the GCX, the turnkey solution
for manufacturing and resharpening gear
cutting tools. The Integrated Gear Tool
Measurement (IGTM) and ANCA’s expertise
in grinding wheel dressing gives customers
the benefit of full control over the high pre-
cision skiving cutter grinding process. First
skiving cutter in tolerance, is the motto.
ANCA’s widely spread area of grinding appli-
cations can be covered with the versatile GCX
and its numerous optional accessories such
as the LaserUltra for profile tools.
An eagerly awaited event at ANCA’s
booth will be the winner announcement of
the Tool of the Year 2023 competition. This
prestigious competition brings together tool
manufacturers from around the globe, who
compete for the title of the best real and vir-
tual tools. The judging process, overseen by
a panel of ANCA and external experts, eval-
uates precision, surface roughness, creativ-
ity, and practical use. The award ceremony
promises to be a highlight of the exhibition,
recognizing the industry’s most innovative
and exceptional tools.
EMO 2023 offers an exclusive opportunity
for industry professionals to explore ANCA’s
latest advancements in grinding technology,
witness revolutionary world premieres, and
engage with experts from the field. Visitors
will also experience exclusive product
launches to be revealed at the show.
MORE INFO www.anca.com
New IPM division
releases new customer
resources brochure
In-Place Machining Company’s new
Measurement & A lignment Ser v ices
Division, comprising Exact Metrology,
OASIS Alignment Services, and ECM: Global
Measurement Solutions, has just released its
new brochure and website page, showcasing
the benefits of having one source for preci-
sion measurement and alignment solutions
in plant and process operations.
These new resources highlight the inno-
vative dimensional metrology, machine
alignment, measurement tooling calibra-
tion, training, and certification capabilities
of these three highly respected industry
suppliers. Providing an integrated approach
In-Place Machining Company’s new brochure and
website page showcase the benefits of having one
source for precision measurement and alignment
solutions in plant and process operations. (Courtesy:
In-Place Machining)
benefits IPM customers with improved col-
laboration between a much larger team of
experienced metrology engineers and tech-
nicians with skills, using a broader range of
highly accurate and innovative 3D metrology
tools and technologies.
With state-of-the-art measurement tech-
nology, cutting edge design, and ISO 9100
& AS9100 Rev D certification, the 3D scan-
ning facilities of the IPM Measurement &
Alignment Services Division can capture
measurements from objects as small as a
medical heart stent to areas as large as a
football field. Using a fleet of innovative
metrology solutions, this new division
offers precision machine alignment, result-
ing in reduced downtime, improved product
quality and minimized waste for many in
the manufacturing and process industries.
Calibrating 3D measurement systems such
as laser trackers, portable arms, etc. on a
schedule will maximize the accuracy and
clarity of the data. Highly trained metrol-
ogy professionals help when clients need to
ensure equipment precision and accuracy to
boost their bottom line.
Capturing information using 3D scan-
ning methods to find measurements of
thickness, accuracy, porosity, and more, is
achieved with the Data Capture software.
It’s compatible with short range, long range,
computed tomography (CT), and coordinate
measuring machine (CMM) scanners as well
as laser trackers. Additionally, post-process-
ing solutions are tailored to fit the needs of
myriad IPM client applications.
Proper machine alignment involves more
than just data collection. Experienced staff
from all the participating companies have
the skills, tooling, and knowledge not only
to provide highly accurate alignment inspec-
tion data, but also to make the necessary
mechanical adjustments. This saves consider-
able time and money during planned outages,
emergency shutdowns, rebuilds and instal-
lations. Using advanced alignment solutions,
IPM helps clients increase operating efficien-
cy through alignment inspections and diag-
nostics, mechanical adjustments, alignment
planning and technical reports.
Calibration services can be performed
onsite at the client’s facility or at one of the
IPM ISO/IEC 17025 Accredited Laboratories.
The Measurement & Alignment Services
Division provides calibration for a wide
array of applications including ISO/IEC 17025
accredited lab, comprehensive reporting, on-
site calibration, ASME standards evaluation,
cleaning and firmware upgrades, portable
instruments and stationary CMMs.
For those who prefer keeping their mea-
surement processes in-house, the company
provides training and certification services.
These include CMS metrology certification,
geometric dimensioning & tolerancing
(GD&T), dimensional metrology, equipment
and maintenance and measurement soft-
ware.
MORE INFO www.inplacemeasureandalign.com
Sandvik digital live
machining demos
go global
Sandvik Coromant, a leading supplier of
tools and technology for the metalworking
industry, has released a new program of digi-
tal live machining (DLM) sessions.
The sessions are hosted virtually from
Sandvik Coromant Centers — a global net-
work of facilities equipped with ultramod-

KISSsoft AG/Gleason Sales

Brian P. Stringer
Phone +1 585 370 4339

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August 2023     11

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INDUSTRY
NEWS
Sandvik Coromant has released new digital learning sessions. (Courtesy: Sandvik Coromant)
ern machinery and technology. The DLM
sessions provide live machining demonstra-
tions, educational presentations, and inter-
active discussions with engineering experts.
DLM sessions have been held by Sandvik
Coromant for a number of years, leaning
on the organization’s extensive machining
knowledge and its global network of Sandvik
Coromant centers. The centers are physical
facilities, staffed by highly skilled engineers
and technicians who have deep expertise in
metal cutting and machining technologies.
The digital sessions are designed to give
attendees from around the world access to
this wealth of knowledge and to help man-
ufacturers and machine shops optimize
their metal cutting processes, save energy,
improve productivity, and reduce costs.
The centers are in key markets, including
the United States, Mexico, Brazil, Germany,
Sweden, India, and China. Offering vir-
tual sessions through DLM coincides with
the inauguration of several new Sandvik
Coromant centers, including a new state-
of-the-art facility that opened in the United
Kingdom in May.
“Customers from around the world will
now have access to the latest digital learn-
ing opportunities from Sandvik Coromant,”
said Helen Blomqvist, president of Sandvik
Coromant. “Historically, these sessions have
been highly successful in providing our cus-
tomers with the knowledge and tools they
need to stay ahead of the competition, and
our growing roster of Sandvik Coromant
Centers gives us more opportunities to share
this knowledge. We are confident that the
12     gearsolutions.com
increased availability of these sessions will
further help our customers optimize their
metal cutting processes and achieve greater
success.”
The new program of virtual sessions will
be available in multiple languages and time
zones, allowing manufacturers and machine
shops to participate from anywhere in the
world.
“Connecting with potential attend-
ees from areas of the world that Sandvik
Coromant Centers do not cover is particu-
larly important — especially for customers
with sustainability and energy-saving goals,”
said Blomqvist. “Optimizing metal cutting
can make a significant difference to the
environmental impact of a business, and
our technical specialists want to share this
knowledge far and wide through our DLM
sessions.”
Sandvik Coromant centers offer a range of
services, including tooling solutions, applica-
tion engineering, and training programs, in
addition to the DLM sessions.
MORE INFO www.sandvik.coromant.com
Platinum Tooling
names new regional
sales manager
Platinum Tooling, the exclusive importer
of Heimatec live tools and angle heads plus
other global brands of precision machine
tool accessories, appointed Frank Twomey
as the company’s regional sales manager.
In his new role, he will oversee all activities
in 18 states in the Northeast, Mid-Atlantic,
and Southeast regions of the United States.
Company President Preben Hansen made the
announcement at the company’s headquar-
ters in Prospect Heights, Illinois.
Twomey graduated from Piedmont
Technical Institute in 1991. His first job was
as a machinist at Ross Industries. He then
took on the role of applications/service/qual-
ity engineer at Walter Grinders and SCM
Group as an applications and service engineer.
Between working as an applications and ser-
vice engineer, he became the CNC manager
of Euro-Composites
Cor poration and
later plant manager
at MTEQ. In 2015,
Twomey took on the
role of district sales
manager for OSG
USA.
Twomey brings
a vast amount of Frank Twomey
experience in aero-
space, medical, machine tool, cutting tool,
metal, and composite industries. His techni-
cal expertise includes programming CNC
machines using Mastercam and Alphacam
CAD/CAM software and is well versed in PLC
programming.
During his career, Twomey studied and
trained in lean manufacturing, value stream
mapping, ISO processes/audits, OSHA compli-
ance, cost reduction, facility/line set-up and
operator training.
Continuing his education in 2020, Twomey
obtained his CPSP (Certified Professional
Salesperson) certification and in 2021
obtained his CPSL (Certified Professional
Sales Leader) certification through NASP
(National Association of Sales Professionals).
“It is great to have Frank on the team as his
expertise will benefit clients across indus-
tries,” Hansen said. “I am excited to see all
that he will achieve.”
MORE INFO www.platinumtooling.com
NSK, KISSsoft AG
join forces to set
gears in motion
NSK started its journey manufacturing the
first ball bearings in Japan in 1916. With
more than 100 years of excellence in engi-
neering, manufacturing, and service, NSK

NSK has provided their extensive bearing data
“catalogue data” for inclusion in KISSsoft software
with release 2023. (Courtesy: KISSsoft)
The following bearing types are covered:
deep groove ball bearings (single row), angu-
lar contact ball bearings (single row), taper
roller bearings (single row), cylindrical roller
bearings (single row), and spherical roller
bearings.
Moving forward, NSK and KISSsoft AG
will continue to update and expand on the
included bearing data.
MORE INFO www.kisssoft.com

UNISIG makes significant

has actively contributed to worldwide indus-
trial development and the preservation of the
environment. NSK is a world-trusted brand
with a global customer base that counts
on the highest in quality and performance.
Currently, it offers a vast product lineup of
more than 200,000 types of bearings.
KISSsoftⓇ gear and transmission system
design software started some 40 years ago
as an in-house software in a Swiss gearbox
company. The company KISSsoft AG by now
supports some 4,000 licensees with best-
in-class gear and transmission design tools.
The software includes internationally recog-
nized calculation standards as well as various
design and optimization options, according
to the slogan “Sharing Knowledge.”
Now, KISSsoft AG announces that NSK has
provided their extensive bearing data “cata-
logue data” for inclusion in KISSsoft software
with release 2023. With this, the engineer
can execute static rating, basic, and modified
life rating based on load capacity numbers in
line with ISO 281 and ISO 76 along with ther-
mal rating. The bearing database in KISSsoft
gives access to up-to-date NSK bearing data
in an easy to use yet detailed manner using
the shaft-bearing system modeler.
investment in technology
and equipment
UNISIG, a global manufacturer of deep hole
drilling machines, has invested $1.5 million
in state-of-the-art technology and equip-
ment for the company’s newly constructed
5,000-square-foot fabrication department.
The expansion supports the company’s
strategy to develop in-house, design-to-fin-
ish production of high-quality sheet metal
components used in UNISIG’s product line.
By producing many of its parts in-house, the

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August 2023     13
INDUSTRY
NEWS

company can preserve and maintain the

quality and quantity of its components while
optimizing the mix of parts that are made
internally versus those that are outsourced
for production.
The investment includes the installa-
tion of fiber laser-cutting equipment, and
a 242-ton capacity press brake with a 7-axis
programmable back gage, all of which use
3D programming and simulation software.
The software and training for the company’s
workforce were part of the investment, along
with the hiring of additional personnel.
The company’s new fabrication capabili-
ties will also serve as an inspiration and cata-
lyst for ongoing development and advances
in machine design that will have an imme-
diate impact on the value UNISIG brings to
its customers now and in the future, said
UNISIG CEO Anthony Fettig. UNISIG has invested $1.5 million in state-of-the-art technology and equipment for the company’s newly
“The most exciting part of this investment constructed 5,000-square-foot fabrication department. (Courtesy: UNISIG)
from my view is the opportunity to funda-
mentally change how we think about the UNISIG’s fabrication enhancements also raw sheet material. To assist department per-
design of fabricated components,” Fettig said. include MIG and TIG welding with advanced sonnel, vacuum sheet lifting equipment and
“Our engineers will be inspired by the manu- digital process control and weld boom with updated bridge crane controls make for easy
facturing innovations generated by the preci- power assist. A modular fixture system pro- material handling.
sion fabrication team and what we can do with vides precision component setup from 3D
these state-of-the-art production capabilities.” models, while a vertical pallet system stores MORE INFO www.unisig.com

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14     gearsolutions.com
Platinum Tooling AD8222 Color 1/4 pg GS 2023
Klingelnberg to present and the integrated Höfler Cylindrical Gear overview of the current key quality indica-

solutions for renewable

Roll Testing Machine R 300 — is ideally suit- tors in their production.
ed for this purpose. The production cell can P 152 is touted as the solution for medi-
energy at EMO be equipped with all machine models in the
Speed Viper series — from the Speed Viper
um-sized gears. The increasing cost pres-
sure on large components for wind power
Under the banner “Innovate manufactur- 80² (dual spindle) to the Speed Viper 300. requires new technologies that will enable
ing,” industry leaders will once again come What’s more, the R 300 is networked with proven principles for high-volume and mass
together at the EMO trade show in Hanover, Klingelnberg’s GearEngine®, making it pos- production of smaller components to be
September 18-23. The EMO is the world’s sible to use roll testing data for production transferred over to large components. The
leading trade show for production technol- evaluation and tolerance management. With newly developed Klingelnberg Precision
ogy, providing full-spectrum coverage of the optionally available R 300 production Measuring Center P 152 closes the gap in
the sector. Systems supplier Klingelnberg monitor, users always have a documented the portfolio between the mid-sized and
will be represented in Hall 11, Booth F51. In
addition to numerous machine demonstra-
tions, Klingelnberg will also be offering a
dedicated lecture series directly at its booth.
In recent years, Klingelnberg has worked
continuously with many of its customers to
analyze the challenges presented by renew-
able energies, such as electromobility and
wind energy, and incorporate them into the
company’s development process. The high
standards in regard to noise behavior of
gears in electric cars are a key aspect that has
come to light based on numerous discussions.
This has led to new products and advances in
existing products that are designed to man-
ufacture application-specific, high-quality
gears on a cost-effective basis, now and in
the future.
The highest profile addition to the
Klingelnberg portfolio is the Höfler Roll
Testing Machine R 300 for torsional accel-
eration testing of gears. At EMO Hannover,
Klingelnberg will also be exhibiting the
Höfler Cylindrical Gear Grinding Machine
Speed Viper and the series P 152, P 40, and P
26 Precision Measuring Centers.
The metrology on the Höfler Cylindrical
Gear Roll Testing Machine R 300 provides a
reliable way to determine the root causes of
gearbox noise. Due to the short measuring
time, it can be easily integrated into any man-
ufacturing process and enables 100 percent
quality control of the gears produced. The R
300 is designed for all roll testing processes
that are relevant for evaluating the running
behavior and noise behavior of gears.
Speed Viper and R 300 combined into one
production cell. A 100 percent quality control
of the gears can be carried out either as an
incoming inspection for assembly or imme-
diately after hard finishing of the gear in pro-
duction. The advantage of the latter option is
that only OK parts are passed on to the next
process step, thus preventing any rejects
from undergoing the finishing process. The
Klingelnberg production cell — consisting
of the Höfler Cylindrical Gear Grinding
Machine Speed Viper, the CompactLoader

August 2023     15
INDUSTRY
NEWS

A production cell, consisting the large precision measuring center model

of the Höfler Cylindrical Gear series.
Grinding Machine Speed Viper,
The latest addition to the family is capable
the CompactLoader and the
integrated Höfler Cylindrical of measuring components with a maximum
Gear Roll Testing Machine R outside diameter of 1 520 mm and work-
300. (Courtesy: Klingelnberg) piece weights up to 8,000 kg with the usual
measurement precision. Despite this heavy
workpiece weight, no special foundation
is required. Klingelnberg has succeeded in
scaling the technology concept of the small
and mid-sized series to the larger component
dimensions. The inherently rigid machine
bed with its 3-point support plays a key role
here. The bed design and floor support are
cleverly designed so that even when loaded
with heavy workpiece weights, the angular
position of the individual machine axes to
each other does not change significantly. The
machine bed’s 3-point support enables the
integration of an active vibration platform
into the machine bed.

A PERFECT MESH
P 40 is the universal all-rounder for reduc-
ing measurement times in series measure-
ment using a hybrid solution. The introduc-
American ingenuity, service and support teamed tion of hybrid metrology with optical pitch
with Japanese efficiency, quality and technology. measurement has significantly reduced
measurement times. It is now possible to per-
form optical pitch measurement on almost
all surfaces using the white light sensor tech-
nology (HISPEED OPTOSCAN) developed by
100+ Years of Manufacturing Gear Hobbing Machines
Klingelnberg and partners, along with other
8 Models of Machines from 50 to 1000mm innovative measuring strategies. Two other
processes for reliably measuring single pitch
deviations are also available.
All Klingelnberg Precision Measuring
Centers in the P 26 to P 65 series can be
optionally retrofitted with the optical sen-
sor (HISPEED OPTOSCAN). For new machines,
the “Ready for Optic” option is also avail-
KN 152 CNC able, providing a factory-installed setup for
GEAR HOBBER
KPS 201 GEAR
SKIVING MACHINE
subsequent retrofitting. Through the sys-
tematic use of the standardized Gear Data
Exchange (GDE) interface when importing
and exporting data and measurement results,
70+ Years of Manufacturing Gear
Klingelnberg has set a higher standard in
Inspection Machines
metrology 4.0 in the area of measurement
Machine Models to 850 OD Capacity results diagnostics and networking of pro-
duction machines and metrology — a system
it calls the Closed Loop.
Compact and tailored to the needs of the
automotive industry, the P 26 precision mea-
suring center has been extremely popular
CLP-35DDSF
GEAR TESTER with customers for more than 25 years. Its
25-year success story was built on a founda-
GTR 25 DOUBLE tion of new measurement and evaluation
FLANK GEAR ROLLER
methods, the implementation of innovative
measuring systems, and uniform quality and
Phone: 586-329-3755 \ Fax: 586-329-3965 reliability.
rodney.soenen@involutegearmachine.com \ www.involutegearmachine.com
MORE INFO www.klingelnberg.com
16     gearsolutions.com
Nidec Machine Tool Exterior of Nidec India
Precision Tools Ltd.’s new
to launch new cutting factory. Nidec Machine Tool to
launch new cutting tool factory
tool factory in India in India to meet growing
demand for automotive
Nidec Machine Tool Corporation, a group and related components by
company of Nidec Corporation, will increasing production capacity
construct a new factory for Nidec India by 1.5 times. (Courtesy: Nidec)
Precision Tools Ltd. (“NMT”), the company’s
cutting tool manufacturer and seller in
Ranipet of India’s Tamil Nadu State.
The new factory, with its production capac-
ity 1.5 times the company’s current manu-
facturing capability, will produce hob cut-
ters, pinion cutters, and other cutting tools.

POWER UP
After its launch, the factory will be able to
quickly supply the company’s customers
in India with its products and meet their
needs in response to the growing demand
for autos, and construction and farming
machinery.
To be constructed on NMTI’s 55,000-
square-meter property in Ranipet, the
southern city of Chennai, the new factory
YOUR GEAR PRODUCTION
will have a f loor space of 2,000 square
meters and be home to production lines
of cutting tools (hobbing, shaping, shaving,
and broaching machines) to cut external
and internal gear teeth, with a production
capacity 1.5 times of its existing facility. In
addition, with a shorter lead time and an
expanded product lineup, the new factory
will meet a wide range of its customers’
needs speedily, while improving recoating
and other after-sales services.
Relatively close to NMTI are Chennai and
Bengaluru, where the country’s auto indus- WE EXCEL at high-speed, high accuracy
try is concentrated. With many two- and continuous generating grinding of cylindrical
four-wheel vehicle manufacturers and sup- gears for turbine and turbo applications:
pliers related to machine tool manufacturers
in those cities, NMTI aims to quickly supply • Gears as large as 1200 mm in diameter
its products to meet the industries’ diverse and module 12 – even beveloids.
needs. Furthermore, with a machine tool
• With technology and software to
show room to be added by autumn this year
grind tip and root relief and other
for customers to see actual products, the new
factory will serve as a sales base of machine modifications without special dressing
tools as well. diamonds.
Since its foundation in 1963, NMTI has • Offering our EXCEL-LENT design
been locally designing, manufacturing, and
software to help you optimize your
selling cutting tools for gear machining for
cylindrical and bevel gear designs.
the past 60 years.
With its efficient and durable cutting
tools gaining popularity from many custom-
ers, the company expanded its businesses as
the market grew larger. This latest invest- Ready to Excel?
ment for production increase is NMTI’s first Contact:
large-scale investment after joining the
Nidec Group in 2021.
815.623.3414 / www.excelgear.com
MORE INFO www.nidec.com
August 2023     17
18     gearsolutions.com
 American
Gear Manufacturers
Association
Free gear education, webinars, economic
reports — What are you waiting for?
I
t is already August. For those of you who run off the fiscal year, you
have about one month to get all your hopes and dreams down on
a spreadsheet to secure funding for next year’s projects. There is
a great deal of uncertainty in the economy right now, so anything
deemed “frivolous” most likely won’t make the cut. As someone who
talks to gear manufacturers and suppliers on a daily basis about the
benefits of joining the American Gear Manufacturers Association, I
can assure you what we offer is not frivolous but a solution to many
of your critical needs.
Check out some of the main reasons (but not all of them) why you
should join AGMA and how putting membership in your budget will
be the best investment you make all year:
MEET YOUR INDUSTRY PEERS, GROW YOUR NETWORK
Our members not only are immediately
brought into the fold of hundreds of other
gear-industry professionals, but they also
get to go to AGMA member-exclusive events.
Events offered include: Annual Meeting in
the spring, the SRN in the summer, curated
tours at manufacturing events, the FTM in
the fall, and our tradeshow every other year. Joining AGMA automati-
cally puts you face-to-face with industry.
GET EDUCATION DISCOUNTS, ACCESS TO WORLD-
CLASS INSTRUCTORS
AGMA offers IACET-accredited courses
so all levels of your company earn CPUs
while they are improving their skillset and
professional development. AGMA offers
online and in-person courses to suit your
travel and budget needs. Your team has the
opportunity to learn everything from the
basics to high-level engineering material.
Do you have a large team that needs special training? AGMA can
help with that by curating on-site courses with our instructors at a
discounted price.
EXCLUSIVE ACCESS TO JOIN ONE OF 23 TECHNICAL
COMMITTEES TO DEVELOP STANDARDS AND WORK
WITH THE INDUSTRY’S TOP ENGINEERS
Standards are the backbone of AGMA and as gear manufacturers and
suppliers, our members deserve to have a say in how they are devel-
oped. By joining our technical committees, you get a front-row seat
to making an impact on your own industry.
Rebecca
Jenny
AGMA
Blackford
Brinkley
Vice President
Director,of
Communications
Membership
AGMA
Engagement &
Communications
DOWNLOAD THE ONLY GEAR-FOCUSED ECONOMIC
REPORTS CURATED BY S&P GLOBAL
The Gear Market Report is a quarter-
ly report included with membership.
Industry data is gathered by the experts
and compiled to offer members the lat-
est information on bookings, shipments,
demand, economic conditions, forecasts,
and more. This report is only available through AGMA and can really
help your team discuss real data about what to expect in the coming
quarters.
EXPOSURE IN OUR PUBLICATIONS
Gear Technology and Power Transmission Engineering are our publications
and by becoming a member, you get discounted rates and exposure
through both of our renowned publications. We want to get the word
out about your latest innovations.
STAY ON TOP OF THE LATEST TECHNOLOGY TRENDS
AGMA prides itself on carving the path to
the future by continuously learning. Our
Emerging Technology series is focused on
keeping our members in the know about
where the tech world is going. From EV
to IIoT and automation to 3D printing, we
have gathered experts from all over the world to share the most
up-to-date data about where our industry is headed. Check out our
white papers.
OPPORTUNITIES FOR REAL SALES LEADS
No one comes to MPT Expo by mistake,
which means this intimate show allows
for real leads, exclusive access to buying
authorities, technical innovators, and the
future of gearing. The entire supply chain
for the power-transmission industry comes
to this show for solutions — your competitors are already signed up.
Get ready for 2023’s show in Detroit, October 17-19.
Free set of standards (23K value), free trade webinars, free com-
mittee involvement, free curated tours at emerging technology
events, unlimited access to a staff that is ready to help you, and the
understanding that when you belong to AGMA, you are part of a fam-
ily. If you want to make a solid investment for this next year (75K in
benefits) or even join now to get the last section of the Gear Market
Report, contact Rebecca Brinkley at brinkley@agma.org.
August 2023     19
Upcoming AGMA Education
Involute Spline Design & Rating
August 15-16 | Anywhere | Online Course
This course will address both geometry and rating of involute splines
of various types. The types of spline joints and their applications will
be discussed. Spline configuration variations, including half depth,
full depth, and special function designs, will be addressed. Both fixed
and flexible spline configurations will be examined in terms of usage
and design. Lubrication methods, including grease, oil bath, and flow-
ing oil, as well as coatings appropriate for various spline applications,
are examined. Shear and compressive stress rating methods are dis-
cussed with analyses methodology presented in both equation and
graphical methodology via various rating charts.
Detailed Gear Design – Beyond Simple Service Factors
August 22-24 | Alexandria, Virginia
There is a distinct difference between “designing” a gear and “opti-
American
Gear Manufacturers
Association
20     gearsolutions.com
mizing” a gear design. In this course, we will address the optimization
process via an understanding of those factors beyond basic banding
and pitting ratings. Optimization may focus on load capacity, econo-
my of production or minimization of overall gear-system envelope.
In this course, attendees will learn how to improve gear designs via
optimization and gain new insight into concepts presented through
illustrations and demonstrations. Explore all factors that go into good
gear design from life cycle, load, torque, tooth, optimization, and
evaluating consequences.
Basic Gear Inspection for Operators
August 23-24 | Chicago, Illinois
This course will provide a solid foundation for anyone going into
gear inspection. Learn the common, current, and basics of the tools
and techniques used to measure and inspect gears. Understand the
four main categories by which a gear is evaluated and classified. Gain
proficiency in understanding gear quality by learning the numerical
scale on which gear design, manufacture, and inspection are based,
and more.

Bevel Gear Systems Design

September 6-7, 13-14 | Live, Online
Learn how to design and apply bevel gears systems from the initial
concept through manufacturing and quality control on to assembly,
installation, and maintenance. Engage in a practical hands-on guide
to the bevel gear design, manufacture, quality control, assembly,
installation rating, lubrication, and, most especially, application.

Registration for 2023

Motion + Power
Technology Expo
Now Open!
The 2023 Motion + Power Technology (MPT) Expo will be
in Detroit, Michigan, October 17-19. Registration for the
event is now open. The Motion + Power Technology Expo
is a three-day show that connects professionals looking
for motion-power solutions with manufacturers, suppli-

Become an AGMA Member ers, and buyers.

AGMA and its members drive power transmission innovation — it’s
a bold vision, crafted with care by members, for members, as we col-
laborate together and shape the future of AGMA and our industry. The
question is: What can AGMA do for you? Contact Rebecca Brinkley at
brinkley@agma.org to find out more about how joining AGMA can
increase your leads, provide your employees with incredible industry
education, connect you to your peers, and inform you with the latest
news, market intelligence, and avenues to grow your brand.
Find new power transmission parts, materials, and
manufacturing processes. Buy, sell, and get business done
with organizations in aerospace, automotive, agricultural,
energy, construction, and more. Forge partnerships at one
of the largest gatherings of CEOs, owners, engineers, sales
managers, and other professionals in the electric, fluid,
mechanical and gear industries.
 More info: motionpowerexpo.com.

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 2023     21
 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.

Aug 15-16 — Involute Spline Design & Rating — Online Course

AUGUST

Aug 16-17 — Wormgearing Committee — Bubikon, Switzerland

Aug 17 — Gear Accuracy Committee — Webex
Aug 22-24 — Detailed Gear Design — Alexandria, Virginia
Aug 23-24 — Basic Gear Inspection for Operators — Chicago, Illinois

Sept 6-7 — Bevel Gear Systems Design (1/2) — Online Course

Sept 12 — Design Basics of Spur & Helical Gears — Online Course
SEPTEMBER

Sept 12 — Helical Enclosed Drives High-speed Units Committee — Webex

Sept 13-14 — Bevel Gear Systems Design (2/2) — Online Course
Sept 14 — Emerging Tech EV Committee — Webex
Sept 18-22 — Basic Training for Gear Manufacturing — Chicago, Illinois
Sept 26 — Gear Accuracy Committee — Webex
Sept 27 — Powder Metallurgy Committee — Webex
OCTOBER

Oct 3 — Helical Gear Rating Committee — Webex

Oct 4-6 — Operator Hobbing & Shaper Cutting — Chicago, Illinois

AGMA LEADERSHIP

Michael Cinquemani: Chairperson Craig Burriss: Industrial Gear Group

EXECUTIVE COMMITTEE

Master Power Transmission

Brian Coclich: CGI, Inc.
Sara Zimmerman: Treasurer
Sumitomo Machinery Corporation of America William Galdo: FLENDER Corporation
Michael McKernin: Chairperson, BMEC
BOARD OF DIRECTORS

Milans Machining and Gear Manufacturing

Adam Gimpert: Helios Gear Products
Todd Praneis: Chairperson, TDEC Joe Goral: Bourn & Koch, Inc.
Cotta Transmission Company, LLC
Wayne Hanna: Brad Foote Gear Works, Inc.
Greg Schulte: Chairperson Emeritus
Bonfiglioli USA Mushtaq Jamal: Bevel Gears India, Pvt, Ltd.
Michelle Maddox: B&R Machine and Gear Corp.
Matt Croson: President
John Perrotti: Gleason Corporation
Amir Aboutaleb: VP, Technical Division
STAFF

Jenny Blackford: VP, Business Division Eric Van Rens: Schafer Industries
Randy Stott: VP, AGMA Media Nicole M. Wolter: HM Manufacturing
Rebecca Brinkley: Director, Membership Engagement & Communications Scott Yoders: Liebherr Gear Technology, Inc.
General requests: webmaster@agma.org | Membership questions: membership@agma.org | AGMA Foundation: foundation@agma.org
Technical/Standards information: tech@agma.org | MPT Expo information: mptexpo@agma.org
22     gearsolutions.com
PRECISION FINISHING SOLUTIONS
FOR AEROSPACE

17.-19.10.2023
Detroit - Michigan

POLISHING, SMOOTHING, ROUNDING, DEBURRING

Blades | Vanes | Blisks | IBRs | Impellers | Gears | Valve parts | Nozzles | Turbine blade roots | Compressor and turbine disks | Fittings | Valves
Hydraulic components | Fly-by-Wire parts | Landing gear components | Coated parts | 3D printed parts | Cutting tools

Stream Finishing Technology

for super heavy duty
■ Deburring, edge rounding
■ Smoothing, high gloss polishing
■ Up to 810 mm diameter
■ Up to 200 kg in weight
■ Integrated pulse finishing
■ Automatic workpiece handling
■ Industry 4.0: Digitalized production

OTEC Precision Finish Inc. OTEC Präzisionsfinish GmbH

sales@otecusa.com • www.otecusa.com info@otec.de • www.otec.de
Tel. +1 401-398-0045 Tel. +49 (0)7082 4911 711 August 2023     23
 MATERIALS LANE WINKELMANN

MATTER
DIREC TOR OF RESEARCH AND DEVELOPMENT
 REM SURFACE ENGINEERING, INC

What to expect from chemically accelerated superfinishing process

When selecting your chemically accelerated
superfinishing process, it is important
to understand and specify your desired
deliverables. In this series of articles, we will
explain two different final surface conditions
that can be produced as well as a recent
case study where potential surface problems
media to provide the mechanical rubbing aspect. The chemical prod-
uct produces a stable, soft conversion coating on the surface of the
gears being processed. The rubbing motion across the gear generated
by the equipment and media effectively wipes the conversion coating
off the “peaks” of the gear’s exposed surfaces but leaves the “valleys”
untouched. No finishing occurs where media is unable to contact
or rub the metal surfaces. The conversion coating is continually re-
formed and rubbed away during the processing step, producing a
surface-smoothing mechanism. This process is continued in the vibra-
tory equipment until the surfaces of the gear are free of asperities. At

were uncovered and addressed by the proper this point, the active chemical product is rinsed from the machine
with a neutral/alkaline solution. The conversion coating is rubbed off
application of isotropic superfinishing. the gear surfaces one final time to produce the superfinished surface.
In this final step, commonly referred to as burnishing, no metal is
removed, just the residual conversion coating.
First in a series
 
Most people envision an extremely reflective, mirror-like tooth

C hemically accelerated/assisted superfinishing, also known as

isotropic superfinishing, was introduced
into the gear industry more than 20 years
flank when they see the drawing call-out an isotropic superfinish, or

ago. Since that time, it has become widely

accepted as a solution for numerous gear fail-
ure modes and performance enhancements.
As a technology becomes more ingrained in
an industry, the new wears off and it becomes
more like a commodity product. Engineering
drawings become more generic, as they
start to incorporate low surface roughness
callouts, but little other guidance. Buyers
start shopping for the lowest cost and fastest
delivery not understanding that, perhaps,
the technology is still evolving and improv-
ing, or that not all processes and suppliers
will produce the same results. Like many
“mature” technologies, isotropic superfinish-
ing is still being improved and advanced in
the gear industry, and if you are not in search
of a particular solution requiring this tech-
nology, you may never know. Figure 1: Mirror-like isotropically superfinished gear with conversion coating effectively removed by the
Isotropic superfinishing is a customizable burnishing step.
manufacturing operation whereby tens or
hundreds of gears can be simultaneously processed in the same piece
of vibratory equipment, or where a small number of highly critical Isotropic superfinishing is a customizable
gears can be processed in an isolated (compartment-based) fashion. If manufacturing operation whereby tens or
all of the raw gears placed in the equipment are identical at the start,
then they are all identically finished at the end of the process. Every hundreds of gears can be simultaneously
gear tooth will have the same surface finish and geometry since the
parts continually and randomly move through the equipment and
processed in the same piece of vibratory
statistically experience the same chemical and media exposure. equipment, or where a small number of
The stock/metal removal is facilitated by an aqueous active chemi-
cal product introduced into the vibratory equipment during the pro-
highly critical gears can be processed in
cess. It works in conjunction with high-density, non-abrasive ceramic an isolated (compartment-based) fashion.
24     gearsolutions.com
MALCOLM MAXEY
PROCESS ENGINEER  RESEARCH AND
DEVELOPMENT GROUP

Ra < 4 µin. (0.1 µm). But, in fact, the gear can look very different and
still meet those generic requirements. See Figure 1 for an example of
a mirror-like isotropic superfinish.
In some instances, a part may appear hazy due to an incomplete
burnish, but still meet the finish requirement. In other cases, the
conversion coating may not be removed at all, generating anything
Figure 2: Superfinished gear retaining the black conversion coating.
from a grey to dark black appearance. See Figure 2 for an example of
an isotropically superfinished gear that retains the black conversion
coating. In some cases, shortcuts and poor process control can lead
to an appearance that masks other finishing issues such as uneven
finishing, or even tooth profile distortion.
The removal of the conversion coating is not necessary, or cost-
effective for some end uses. The automotive industry demands fast
tact times and low cost, so the burnishing step may be eliminated to
meet these requirements while still delivering an isotropically super-
finished gear that performs much better than it would in a ground or
lapped condition. These types of gears typically do not receive second-
ary processes after isotropic superfinishing such as coatings, so the
presence of any residual conversion coating is not an issue.
In more demanding industries, coatings are becoming more preva-
lent. In some cases, the webbing is coated for corrosion resistance.
Additionally, tooth flank coatings are being evaluated for potential
performance enhancement. When combining isotropic superfinish-
ing and coating technologies, surfaces that
retain the conversion coating can raise adhe-
sion concerns.
In one recent project, the Gear Research
Institute (GRI) at Penn State University
reached out for assistance reviewing test gears
that had been isotropically superfinished to
remove surface damage resulting from the
shot peening of the tooth flanks. These gears
were destined for use to evaluate several coat-
ings through fatigue testing. Upon receipt at
GRI, the gears appeared to meet the surface
finish requirements, but they retained the
black conversion coating as shown in Figure
2. The team at GRI was concerned with the
appearance, as they typically receive test
gears sent for isotropic superfinishing that
are mirror-like, as shown in Figure 1. Their
main concern was that the coatings may not
adhere properly thus ruining their testing and
the expensive gears. These gears had been not
processed by REM, but REM has been a mem-
ber of the GRI Aerospace Bloc for many years and is recognized as an
expert in the field of gear surface enhancement and isotropic super-
finishing, so GRI reached out to us to evaluate these gears.
After a quick review of the project with the team and GRI and
their customer, it was determined that these gears would be sent to
REM for further evaluation. Upon receiving the gears, REM was able
to confirm that these gears had been improperly or incompletely bur-
nished. After a discussion with GRI and their customer, REM agreed to
burnish the parts to the mirror-like appearance GRI was accustomed
to receiving. In the next installation of this article, we will review
what we found hiding under the thick conversion coating.

ABOUT THE AUTHORS

Lane Winkelmann joined REM Surface Engineering, Inc. in 1996. He has held multiple positions there, including director of services where he
managed three ISF® Service Centers covering the U.S. and European markets. He is currently director of research and development. During
his career, Winkelmann has developed numerous products and processes as well as has co-authored several patents and papers on the use of
superfinishing. He received a B.S. from Texas A&M University in 1991, and his M.B.A. at Tulane University in 2005. He can be contacted at
lwinkelmann@remchem.com.
Malcolm Maxey is a process engineer who works in the Research and Development Group with more than 20 years of engineering and account
management experience in the automotive, petrochemical, and telecommunications fields. As a process engineer, Maxey verifies and develops work
procedures for isotropic surface finishing processes. In addition, he is responsible for the procurement management of raw materials required for
process-aid manufacturing. Maxey has a B.S. in mechanical engineering from Prairie View A&M University, Prairie View, Texas.

August 2023     25
 TOOTH BRIAN DENGEL
TIPS GENER AL MANAGER  KHK-USA
What is a gear rack?
Gearing 101: A primer on gear racks, what they
are and how they’re used.
A gear rack is a type of gear on which gear teeth are cut on one face
of a bar. The bar can be square, round or rectangular in cross sec-
tion and the teeth can be either parallel to the base or set at an angle.
They are a simple and common type of element in mechanical drive
systems and are always paired with a pinion.
Gear racks convert power and motion from rotary motion into
linear motion. For straight tooth gear racks, the mating pinion must
be the same pitch, and the same pressure angle. When the gear rack
teeth are helical, the pitch, the pressure angle, and the helix angle
of both the pinion and the gear rack must be the same; however, the
direction of the helix angle of each component must be opposite.
The teeth of a gear rack are cut using a rack milling machine.
The milling head machines a section of rack and then indexes to the
adjacent section until the rack is completed. The maximum length
of a rack is only limited by the length of the milling machine. Gear
racks can be produced from various materials, including steel, brass,
A gear rack is a type of gear on which gear teeth are cut on one face of a bar.
26     gearsolutions.com
bronze, or plastic, and depending on the application, they can be hard-
ened based on the requirements for strength and durability.
The geometry of a gear rack is defined by several parameters. In
a theoretical sense, a gear rack is just a spur gear with an infinite
pitch diameter. The calculations vary depending on whether the teeth
are produced in the normal system or the transverse system. Table
1 details the calculations for a gear rack and a profile shifted pin-
ion. This gear tooth modification factor is not typically applied but is
sometimes used to manipulate the center distance of a gear rack and
pinion. In most applications, this value is set to zero for the pinion.
The first value needed to produce a gear rack is the pitch. In the
metric system, this is known as the module. As the value of the mod-
ule increases, the size of the gear tooth increases. In the English stan-
dard system, the pitch of a helical gear is known as the diametral pitch
(DP). It represents the number of teeth that are found on a gear with
a one-inch reference diameter.
The pressure angle is the angle between the line of action of the
gears and the tangent to the pitch circle. It determines the contact
between the teeth of the gears and affects the load-carrying capac-
ity and efficiency of the gears. In the English system, helical gears
Table 1: The calculations of dimensions of a profile shifted spur gear and a rack.
typically have values for pressure angle of 20 degrees or 14 degrees
30 minutes. For metric helical gears, the pressure angle is typically
20 degrees.
The number of teeth for the pinion is chosen by the end-user based
on the speed ratio that is desired for the application. Each rotation of
the pinion will travel a specific linear distance along the gear rack. A
pinion with a smaller number of teeth will need to rotate faster than
a larger pinion in order to travel the same distance.
The addendum of a gear rack tooth is the linear distance between
the pitch height and the tooth tip. Correspondingly, the dedendum
is the linear distance between the pitch height and the tooth root.
The sum of the addendum and the dedendum determines the total
tooth height.
Although not shown in Table 1, the value for backlash is important
for gear racks. This value measures the distance between the pinion
gear teeth and the rack gear teeth when they are not in contact. It
is necessary to have a minimum amount of backlash for the gear
teeth to mesh properly and for lubricant to engage with the rack and
pinion at their point of contact. As rack and pinion systems are typi-
cally used for positioning applications, the accumulation of backlash
errors can have a significant impact on position accuracy. Additional
mechanisms such as optical encoders are incorporated into rack and
pinion systems in order to maintain positional accuracy.
ABOUT THE AUTHOR Brian Dengel is general manager of KHK-USA, which is based in Mineola, New York. Go online to www.khkgears.us
The design of gear rack involves determining the pitch height,
module, pressure angle, addendum, dedendum, and backlash. These
factors are dependent on the desired speed ratio, power transmission
requirements, and the design of the mechanical system. Gear racks
will only transmit power between perpendicular axes. As the pinion
rotates, the teeth engage and transmit torque from the pinion to the
gear rack. If the rack is fixed and the pinion is rotated clockwise,
then the pinion will translate to the right. If the pinion is fixed and
rotates clockwise, then the rack will translate to the left. The distance
of translation along the rack is equal to the pitch circumference of
the pinion. When using a normal module, this distance is fractional.
When using a circular pitch instead of module, you can achieve a
fixed translation. For example, a module 3 pinion with 30 teeth will
translate 282.74 millimeters per rotation, whereas a CP10 pinion with
30 teeth will translate exactly 300 millimeters per rotation. Another
way to achieve a fixed rotational value is to use a helical rack and
pinion with a helix angle of 19° 31’ 41” as this value converts module
to circular pitch as well.
Gear racks are a commonly used element in mechanical systems
because they are simple in design, efficient in operation, and cost-
effective. Understanding the technical definitions and design prin-
ciples of gear racks is essential for anyone working with mechanical
systems.
August 2023     27
 HOT D. SCOTT MACKENZIE, PH.D., FASM

SEAT
SENIOR RESEARCH SCIENTIST–METALLURGY 
QUAKER HOUGHTON INC.

Nitrogen-methanol atmospheres – storage and control

Understanding the physical parameters
of methanol, and the different measuring
techniques, will enable precise methanol (and
atmosphere) control.

I n this column, I will discuss the storage and control of methanol to

create nitrogen methanol atmospheres.

INTRODUCTION
Nitrogen-methanol atmospheres are used frequently when natu-
ral gas is unavailable. While excellent and repeatable production of
endothermic atmospheres is possible, there are some caveats that
must be understood to produce an endothermic atmosphere of the
proper composition.
A typical nitrogen-methanol system is usually composed of a meth-
anol storage tank, cryogenic nitrogen tank, vaporizer, and methanol
delivery system (pump or pressure). A control panel comprised of a
series of flowmeters is also included. This is shown in Figure 1.

METHANOL DELIVERY SYSTEMS

In early nitrogen-methanol systems, nitrogen was used to pressur-
ize an underground methanol tank to “push” the methanol to the
furnace control panel for each furnace, then to each furnace. Often, Figure 1: Typical nitrogen-methanol installation.
due to distances involved, pressure inside the methanol tank had to
be maintained at approximately 60 psi (414kPa). This caused several
problems. First, a large amount of nitrogen was consumed over and
above that required for normal processing. This was the result of
bleeding the pressurized methanol tank during filling, and the addi-
tional nitrogen required to pressurize the tank as the methanol level
dropped. In addition, due to the high vapor pressure of methanol,
the nitrogen-filled space above the methanol became saturated with
methanol. This saturated nitrogen became an additional fire hazard
when the methanol tank was vented for any reason.
A second problem with a pressurized methanol delivery system is
that methanol absorbs nitrogen readily, especially at the pressures
used. This can become exaggerated as the methanol tank level lowers,
and furnaces are taken offline. As the pressurized methanol is pushed
to the control panel and furnace, pressure drops occur at each pipe
elbow, valve, or flowmeter. At each of the pressure drops, nitrogen
will come out of solution in the form of bubbles, making control dif-
ficult. The problem of nitrogen bubbles, apparent at the methanol
flowmeter, made precise control difficult. Replacing the pressurized
system with a pump, and only using low-pressure nitrogen to inert
the top part of the tank reduces the amount of nitrogen dissolved in
methanol.
One problem with venting the methanol tank, whether as a blan-
ket or used to push the methanol to the furnace, is that the vented
nitrogen contains a high percentage of methanol. From the low
flashpoint of methanol, this would be considered a volatile organic
compound (VOC). These vapors can be collected, and the methanol

28     gearsolutions.com

Figure 2: Variation of dynamic viscosity of methanol as a function of temperature.
Figure 3: Correction factor of indicated flow, for a methanol flowmeter calibrated
at 70°F (21.1°C).
recovered, using the cold nitrogen to condense the methanol. This
nitrogen can be routed back to blanket the system.
Regarding the nitrogen system, it is very important that the vapor-
izers on the nitrogen tank are sized appropriately for the maximum
purge flow rate for all furnaces. This is critical in case of an extended
power failure to properly purge the furnaces with atmosphere, and
maintain a positive pressure in the furnaces as the temperatures in
the furnaces fall. This also provides protection of work in the furnaces
and helps minimize oxidation of parts.
METHANOL TANK STORAGE & INSTALLATION
Methanol storage tanks can be either above ground, or below ground.
Where depends on either local fire or environmental regulations.
Many fire codes (at least previously) required underground storage
tanks. These tanks at, at a minimum, were double walled, with intrin-
sic sensing. Modern environmental regulations require above ground
storage, with containment. In many respects, the storage of methanol
is like that of gasoline.
For larger underground tanks, once the pit has been dug, before
the tank is covered with dirt and asphalt, it should be immediately
filled with methanol. It should also be fully strapped down with con-
crete piers on a concrete stab. Failure to do so before filling the tank
with methanol may result in the tank floating out of the pit if a heavy
rain or ground water fills the pit (don’t ask me how I know this).
Methanol is routinely stored in above-ground, internally baffled
tanks. These tanks must be properly grounded to avoid ignition from
static electricity. Nitrogen is used to inert the space above the liquid
methanol.
Methanol burns with an invisible flame. First responders should
have remote heat detection capability. The installation is recom-
mended to have some sort of remote temperature sensing capability.
ABOUT THE AUTHOR D. Scott MacKenzie, Ph.D., FASM, is senior research scientist-metallurgy at Quaker Houghton. He is the past president
of IFHTSE, and a member of the executive council of IFHTSE. For more information, go to www.quakerhoughton.com.
Methanol storage should be in a dedicated area, away from build-
ings. This area should be specifically marked off and placarded as a
hazardous area. Safety measures should be readily available for expo-
sure, spillage, and fire.
METHANOL CONTROL
In most nitrogen-methanol control panels, rotameters are used to
control the amount of methanol and nitrogen. In a rotameter, a float
is installed in a vertical tube and the fluid flows around the float. The
float is raised due to the flow. This measurement technique is depen-
dent on viscosity and temperature. Most flow meters are calibrated
for a specific fluid, at a specific temperature and pressure. For liquids,
the pressure is critical because liquids are incompressible.
However, viscosity is important. Viscosity is strongly influenced
by temperature, and methanol shows a large variation in dynamic
viscosity as a function of temperature (Figure2).
This means that at temperatures other than the calibrated temper-
ature, the indicated flow rate of the methanol is incorrect. Depending
on the incoming methanol temperature, the variation can be very
significant. A scale factor, determined by taking the viscosity at the
calibration temperature, divided by the viscosity at another tempera-
ture, can then be applied to the displayed reading on the flow meter.
An example of the correction factor for different incoming tempera-
tures of methanol is shown in Figure 3.
To minimize the variation of temperature, and resulting changes
in viscosity, the use of a small chiller can be used to ensure that the
temperature is maintained at the calibration temperature. This will
ensure that precise metering of methanol can be accomplished.
CONCLUSIONS
In this article, we have described some of the issues with storage
and control of methanol used to create nitrogen-methanol endo-
thermic atmospheres. Safety during storage and having appropriate
engineering controls is important to protect people and equipment.
Understanding the physical parameters of methanol, and the differ-
ent measuring techniques, will enable precise methanol (and atmo-
sphere) control.
Should you have any questions regarding this column, or sugges-
tions for any future columns, please contact the author, or the editor.
REFERENCES
[1] D. Aronowitz, D. W. Naegeli and I. Glassman, “Kinetics of the Pyrolysis of
Methanol,” J. Phys. Chem., vol. 81, no. 25, pp. 2555-25559, 1977.
[2] D. Aronowitz, R. J. Santoro, F. L. Dryer and I. Glassman, “Kinetics of the
oxidation of methanol: Experimental results semi-global modeling and
mechanistic concepts,” Symposium (International) on Combustion, vol. 17,
no. 1, pp. 633-644, 1979.
[3] P. E. Liley, “Thermodynamic properties of methanol,” Chem. Eng. , vol. 11,
no. 59-60, 1982.
[4] Methanol Institute, Methanol Safe Handling Manual, 5th ed., Alexandria,
VA, 2023.
[5] NFPA, “NFPA 30: Flammable and Combustible Liquids Code,” National
Fire Protection Association, 2024.
[6] Occupational Safety and Health Administration, CFR 49 1910.119: Process
safety management of highly hazardous chemicals.
August 2023     29
ISSUE POWDER METAL GEARS / CHAMFERING & DEBURRING
FOCUS

EXTENSIVE
APPLICATIONS
OF PM GEARS

30     gearsolutions.com
Powder metal gears boast many advantages over
more traditional gear-manufacturing processes.
By ROBERT GAVRAN

P
owder metallurgy is a manufacturing process
that involves compacting metal powder under
high pressure and then sintering them at ele-
vated temperatures to form solid components.
Miba Sinter USA uses a range of metal powders such as
iron, steel, and alloys, depending on the specific appli-
cation requirements. Powder metal gears are widely
used in various industries such as automotive, indus-
trial equipment, and power-transmission applications.
The core process of powder metallurgy includes
powder mixing, tooling, powder compacting, green
machining, sintering, sizing, packaging, and final
inspection. Secondary process includes inductive
hardening, heat treatment, machining and nitriding.
(Figure 1)

GEAR TYPE
Powder metal gears, like gears produced using other
manufacturing techniques, can have a variety of tooth
profiles depending on the specific application require-
ments. The tooth profile is crucial as it determines the
gear’s performance in terms of load capacity, efficien-
cy, and noise characteristics. Some commonly used
tooth profiles for powder metal gears include:
Spur gears have straight teeth that are parallel to
the gear axis. They are the simplest and most common
type of gear. Spur gears are suitable for transmitting
power between parallel shafts and provide high effi-
ciency but can generate noise due to their engagement
characteristics. (Figure 2)
Figure 2: Spur gear
Helical gears have teeth that are cut at an angle to
the gear axis, resulting in a helix shape. This helical
tooth profile allows for smoother and quieter opera-
tion compared to spur gears. Helical gears can transmit
power between parallel or non-parallel shafts, and they
provide higher load-carrying capacity. (Figure 3)
These are just the most common examples of tooth
profiles commonly used in powder-metal gears. It’s
important to note the selection of the tooth profile

CORE PROCESS

SECONDARY PROCESS
Figure 1: The core process of powder metallurgy includes
powder mixing, tooling, powder compacting, green machining,
sintering, sizing, packaging, and final inspection. Secondary
process includes inductive hardening, heat treatment,
machining and nitriding.

August 2023     31
depends on factors such as the application
requirements, desired gear ratio, torque
transmission, and efficiency considerations.
Design engineers typically consider factors
such as load distribution, noise generation,
efficiency, and manufacturing feasibility
when determining the appropriate tooth
profile for a specific powder metal gear appli-
cation.
POWDER METAL MATERIAL
When it comes to material choices in powder
metallurgy for gears, several factors need to
be considered:
 Mechanical Properties: Gears are sub-
jected to significant stresses, including
bending, torsion, and fatigue. Therefore,
the chosen material must possess adequate
strength, hardness, and wear resistance.
Figure 3: Helical gear
Common materials used in powder metal-
lurgy for gears include low-alloy steels, iron-based alloys, and some
non-ferrous alloys.
 Density: The density of the powder metallurgy gear material
affects its ability to transmit power efficiently. Higher density mate-
rials offer better strength and load-bearing capacity. However, the
density must be balanced with other factors such as cost and pro-
cessability. (Figure 4)
 Lubrication and wear: Gears require lubrication to minimize fric-
tion and wear. Some powder metallurgy materials possess inher-
ent self-lubricating properties, such as copper-based alloys or iron-
copper-graphite compositions. These materials reduce the need for
external lubrication and improve the gear system’s performance
and durability.
 Cost: Powder metallurgy often leads to cost savings compared
to traditional manufacturing methods. The material cost, as well
as the ease of processing and secondary operations such as heat
treatment, must be evaluated to ensure an optimal balance between
performance and cost.
Miba powder metal gears are known for their excellent strength,
durability, and precision. With its patented densification process, the
company achieves a density of >7,6g/cm3. The high density is mainly
needed for gears in the e-drive and automotive industry. Miba’s patent-
ed densification process can be used for inner and outer splines. Due
to this densification process, a strength of solid steel can be achieved
on the surface of its powder metal gears. (Figure 5)
Figure 4: Common materials used in powder metallurgy for gears include low-alloy
steels, iron-based alloys, and some non-ferrous alloys.
32     gearsolutions.com
APPLICATIONS
Powder metal gears find extensive applica-
tions in various automotive systems, includ-
ing:
 1. Transmissions: Powder metal gears
are widely used in automatic and manual
transmissions, providing reliable and effi-
cient power transfer between the engine
and wheels. Their high strength and
wear resistance ensure smooth shifting,
improved gear engagement, and prolonged
transmission life.
 2. Electric powertrains: As the automo-
tive industry shifts toward electric vehicles
(EVs), powder metal gears play a vital role in
electric powertrain systems. These gears are
employed in electric motor drives, gearbox-
es, and differentials, delivering the neces-
sary torque and speed required for optimal
EV performance.
 3. Steering systems: Powder metal gears are employed in
steering systems to transmit power from the steering wheel to the
wheels. Their durability, precision, and quiet operation contribute
to responsive and accurate steering control.
Figure 5
VALIDATION OF POWDER METAL GEARS
The validation process of powder metal gears involves comprehensive
testing and analysis to assess their performance characteristics. The
goal is to verify the gears meet the desired specifications and can
withstand the intended operating conditions. The process typically
consists of the following stages:
DESIGN VERIFICATION
The initial step involves verifying the gear design using computer-aid-
ed engineering (CAE) tools. Finite element analysis (FEA) is employed
to simulate the gear’s behavior under different loads, speeds, and
operating conditions. This analysis helps identify potential design
issues, such as stress concentrations, deflection, or excessive wear,
which can be addressed before physical prototyping.
MATERIAL VALIDATION
Powder metal gears are manufactured using specific metal pow-
ders and additives. The materials used must undergo rigorous test-
ing to validate their properties and suitability for gear applications.
Mechanical tests, such as tensile strength, hardness, and fatigue test-
ing, are conducted to ensure the powder metallurgy process results
in materials with the required strength and durability.
COMPONENT TESTING
Once the gears are manufactured, a series of component-level tests
are performed to evaluate their performance. These tests include:
 Gear tooth strength: The gears undergo tests to evaluate their
resistance to tooth breakage or wear. This involves subjecting the
gears to high loads and measuring the tooth deflection, stress dis-
tribution, and fatigue life.
 Gear mesh efficiency: The meshing characteristics of the gears
are assessed to determine their efficiency and minimize power loss
due to friction. This is achieved by analysing the gear meshing pat-
terns, backlash, and contact ratio.
Figure 6: PM tech is considered more environmentally friendly compared to other manufacturing processes.
(Courtesy: Powder Metallurgy Review, July 6, 2016)
 Noise and vibration analysis: Powder metal gears are evaluated
for noise and vibration levels during operation. Accelerometers and
sound level meters are used to measure and analyze vibrations and
noise generated by the gear system. This helps identify potential
issues and optimize the gear design for quieter operation.
SYSTEM-LEVEL VALIDATION
Powder metal gears are integrated into the targeted system, such as
transmissions or drivetrains, for comprehensive system-level vali-
dation. This involves subjecting the gears to real-world operating
conditions, including varying speeds, loads, and temperatures. The
performance and durability of the gear system are evaluated through
extensive testing, including endurance tests, thermal cycling, and
accelerated life testing.
COMPLIANCE WITH STANDARDS
Powder metal gears must adhere to industry standards and regula-
tions. Validation includes verifying compliance with standards such
as ISO, AGMA, IATF, or specific automotive OEM requirements. These
standards define parameters such as gear quality, material proper-
ties, and performance criteria, ensuring consistency and reliability
across the industry.
PM BENEFITS
What are the benefits using powder metallurgy technology for your
gear?
ABOUT THE AUTHOR
Robert Gavran is with Miba. He started his career in 2011 with powder metal gears and worked on many different gear projects mainly for the
automotive industry. Gavran is in Detroit, Michigan.
 Material selection: Miba uses a range of metal powders such as
iron, steel, and alloys, depending on the specific application require-
ments. These materials offer high strength, wear resistance, and
fatigue resistance.
 Precision manufacturing: Miba employs advanced techniques in
powder metallurgy to ensure tight tolerances and high dimensional
accuracy. This precision manufacturing process allows for the pro-
duction of complex gear geometries with minimal post-processing.
 Cost effectiveness: Powder metal gears offer cost advantages
compared to traditional machined gears. The ability to produce
complex geometries and the elimination of secondary operations
like machining and heat treatment contribute to cost savings.
 Improved efficiency: Miba powder metal gears are designed to
minimize friction and wear, resulting in
improved efficiency and reduced power
losses. They also offer excellent noise and
vibration damping properties.
 Customization: Miba can tailor the
design and properties of powder metal
gears to meet specific customer require-
ments. This flexibility allows for optimized
gear performance in terms of load capacity,
speed, and noise reduction.
 Reliability: Miba powder metal gears
undergo rigorous testing and quality con-
trol procedures to ensure high reliability
and long service life. They are designed to
withstand demanding operating conditions
and provide consistent performance.
 Light weight: Compared to solid steel,
the weight of powder metal gears is lower by about 10 percent.
 Enhanced noise and vibration damping: The inherent porosity of
powder metal gears acts as a natural dampening mechanism, reduc-
ing noise and vibration during gear operation. This makes powder
metal gears particularly suitable for applications where noise reduc-
tion is critical, such as transmissions and drivetrain systems. The
ability to dampen vibrations contributes to increased driver comfort
and a quieter driving experience.
 Design flexibility: Powder metal technology enables the pro-
duction of intricate gear shapes and features that are difficult or
impossible to achieve with traditional manufacturing methods. This
design flexibility allows for optimized gear performance, includ-
ing improved load distribution, reduced weight, and enhanced
efficiency.
 Consistency and quality: Powder metal technology offers excel-
lent control over the manufacturing process, resulting in consistent
gear quality. The process enables tight tolerances, high dimensional
accuracy, and uniform material properties throughout the gear. This
consistency ensures reliable performance and reduces the need for
post-processing or secondary operations.
 Environmental sustainability: Powder metal technology is con-
sidered more environmentally friendly compared to other manu-
facturing processes. It generates less waste, consumes less energy,
and reduces the need for raw materials. Additionally, the ability
to recycle and reuse excess powders contributes to overall sustain-
ability. (Figure 6)
August 2023     33
 PRECISION
MACHINING
WITH ABRASIVE
BRUSHES

Cutting tools receive an edge prep treatment

after new manufacture or reconditioning. A sharp
edge on a cutting tool will deteriorate quickly
and cause chatter. A small radius disperses the
pressure along the length of the cutting edge and
will provide a smoother cut, longer life, and better
finishes. Shown here are carbide inserts typically
receiving an edge break of 0.001” ± 0.0002”.
Diamond brushes with 600 grit and 0.014” filament
are a good starting point. Diamond brushes are
available in many configurations. (Courtesy: CDMC)

34     gearsolutions.com
Abrasive brush machining is a cost-effective,
time-reducing method that can complement many
workpiece types and solve the problems of many
chamfering, deburring, or finishing challenges.
By ADAM MUTSCHLER and ERIC MUTSCHLER

A
brasive brushes are useful tools in all sorts of with two elements:
applications. They’ve been around for many  Impact: This is determined by the size, shape, and
years and are used every day in all types of trim length of the bristle itself (the nylon carrier).
chamfering, deburring, and finishing processes  Cut: This is determined by the grit size and type
but when properly applied, they can be used as a preci- of grit, as well as the concentration.
sion machining process holding incredible tolerances. Other important aspects include placement of the
Their application is often misunderstood and applied brush and, most importantly, maintaining proper
in ways that set the brush up to fail. engagement of the brush once all process parameters
What is an abrasive brush? are set. If the bristle can access the area requiring
These are brushes made from a wide variety of fila- the work, it can succeed. If there are obstructions,
ments fabricated into a wider variety of power brushes. the bristle may not reach the intended area. The typi-
They can be radial (wheel) brushes, disc (cup) brushes, cal response to this is more pressure or engagement,
end (face) brushes, bottle brushes, as
well as other more specialized configu-
rations.
The filament is made by mixing
nylon and abrasives grain and then co-
extruding the filaments. This allows the
abrasive to be present throughout the
filament as the brush wears, constantly
presenting fresh grains as the nylon
breaks down.
Common abrasives are silicon car-
bide (most common), but more recent
arrivals include ceramic grain as well
as CBN and diamond grains.

BRUSH VARIABLES
Brushes can be made to perform as you
need them to. The variables include
diameter, density, general construction
(disc-type brushes), and trim length.
Bristle filament types can be round or
Ceramic chips require a very specific controlled edge radius. The radius size as
rectangular, straight or crimped. Each
well as shape are both held to a ±0.002” tolerance. (0.0075” target). The radius
configuration has a very specific use and must be a full radius equally spaced. This application used a silicon carbide 320
behavior when applied to the workpiece. grit brush to succeed as anything more aggressive would chip the brittle ceramic.
Additionally, grit size, filament diame- This process replaced the tedious grinding solution that was used for years and
ter, and concentration (ratio and size of had a 50 percent scrap rate due to chipping. (Courtesy: CDMC)
abrasive grains relative to nylon carrier)
all play a role in the end results. There are endless com- which usually leads to more problems, including
binations that can be made, and minor adjustments improper chamfer, premature brush wear, or wear-
can make significant changes in performance. ing the brush irregularly. Nylon abrasive brushes
typically work only on the edges of a workpiece with
HOW DOES A NYLON ABRASIVE the exception of the ceramic and diamond media.
BRUSH WORK? The radius will generate, and the base material will
Placement and control of engagement are critical for not be disturbed or changed. The edge will generate
proper results. The brush works best when it passes the quickly at a small level and as it increases, the rate of
edge perpendicularly. It does not work as effectively cut will slow down as the edge becomes larger. Other
when contacting the edge parallel. The filament cuts media types are designed to be more aggressive and

August 2023     35
 Precision machining with abrasive
brushes requires control over
variables. This is critical.
Tolerances of 0.0001” can
be held with abrasive
brushes.
Shown here is a carbide drill also with edge prep applied. In this case, the manufacturer wanted a 0.0015” full radius applied on both angles of the drill point (as shown).
(Courtesy: CDMC)
can remove base material when brushed heavily or not properly
controlled.
VARIABLES, VARIABLES, VARIABLES
Precision machining with abrasive brushes requires control over vari-
ables. This is critical. Tolerances of 0.0001” can be held with abrasive
brushes. The conditions under which these tolerances are held are
highly controlled. Specialized machines are available to perform
these tasks and achieve these results.
Variables range from consistent and qualified brushes to con-
trolled machine parameters that monitor and adjust the engagement,
dwell time, and position of the workpiece.
Brush tolerances you may not know about. It’s all about control.
As with any cutting tool, consistency and control are key to con-
trolling tight tolerance requirements. Brushes are often overlooked,
and their tolerances are misunderstood until you are controlling a
radius to a micron level.
Brushes are made with a filament that has a tolerance of ±10 per-
cent. This can be huge in both impact results as well as access to roots
and corners. A more controlled tolerance filament is available at a cost
and should be employed as a part of the overall process development.
Media concentration is also allowed a ±10-percent tolerance as a
standard product. This is also huge and can affect results dramati-
cally. We have proven this in many applications using off-the-shelf
36     gearsolutions.com
brushes. To be fair, in most cases, these tolerances will not be noticed.
But they will be in precision-radius applications. We source media
from Europe that is verified and provided within stringent tolerances
in diameter, nylon type, and concentration of media.
Brush construction varies from manufacturer to manufacturer.
The methods used to construct a brush are typically proprietary, and
tolerances are not generally provided. Working closely with trusted
sources, brush construction can be controlled to an acceptable level.
Consider a brush is made in an automated fashion. Bundles of fila-
ment are weighed and assembled and inserted into the brush body.
These bundles can vary to the point of creating a very different
result in the cut. Controlling the bundles and construction are also
key to success.
CASE IN POINT
Our application team was approached by a customer that had a chal-
lenging requirement. Very specialized materials used in products
that fly required some unique results to be obtained. These results
required the application of a radius on a square edge of a spline.
The tolerances were 0.005” full radius +0.005” -0.000”. Applying a
radius to these edges included several angled surfaces as well as
long lengths of spline teeth. Applying this level of tolerance was
not something that a manual operator can accomplish consistently
by applying the part to a pedestal grinder, and this proved to be

An example of pump gear with a radius. (Courtesy: CDMC)
true. The variables between operators, skill level, fatigue, and the
overall difficulty of the repetitive motions make this unpredictable.
Although not an ultra-tight tolerance, consistency was an absolute
requirement.
The part had a set of spines each with lead and trailing angles. Each
of the edges needed to be chamfered equally to meet the print require-
ments. This is a total of 12 surfaces on each part to be chamfered.
We chose a ceramic brush to do the job. A Pferd 120 grit x 0.028”
diameter crimped filament was capable of reaching the roots due to
the small filament diameter. The ceramic grit cut predictably, and
the process was developed. The results were that all of the edges were
ABOUT THE AUTHORS
Adam Mutschler has been the president of Cleveland Deburring Machine Co. since 2010 and has been involved in deburring technology for
20 years. Eric Mutschler is the VP of sales for Mutschler Edge Technologies. He has been involved in deburring and edge prep technology for
almost 40 years.
predictably capable within the allowable tol-
erances using a 1.67 Cpk.
CHOOSING A SUITABLE MACHINE
PLATFORM TO APPLY THIS LEVEL
OF CHAMFER
This is a high-demand, high-accuracy applica-
tion. Developing the process is one challenge
but applying the chamfers is entirely another.
We chose the CDMC zero set robot deburr-
ing machine. Using the dependable Fanuc LR
200 unit proves to be a reliable and trouble-
free approach with minimal maintenance
required.
Applying the brush to the workpiece
required wear control as the brush wears as
well as the correct placement of the brush
relative to the part. The zero set is designed
for such applications. The brush is applied
to the work with a precision pneumatic cut-
ting head that uses differential pressure to
maintain exact levels of contact allowing the
bristles to do their job. As they wear, the pres-
sure compensates for the reduced diameter
and continues to apply the exact pressure
assuring results. A reversing air motor drives
the brush and provides consistent RPM along
with a compact size.
CONTROL IS KING
This type of application requires collabora-
tive teamwork between the customer and
the machine supplier. Having capable and
committed people on both sides will make
success much easier to attain. All points of
the process must be maintained and cannot
be deviated from to maintain capable results.
If brushes are not as defined, there will be
problems. If the machine is not functioning
as it should, there will be problems.
Defining and maintaining a level of con-
trol is the recipe for precision machining
with nylon abrasive brushes.
CONCLUSIONS
“A brush is a brush is a brush” can be a true statement depending
on the application. The end results have much to do with the under-
standing of how exactly the brush is, its placement to the part, and
the control used to apply it to the workpiece.
To achieve the results of high tolerance control, rules must be fol-
lowed. In doing so, the repeatability of high tolerances is quite within
the capability of most shops.
Abrasive brush machining is a cost-effective, time-reducing meth-
od that can complement many workpiece types and solve the prob-
lems of many edge finishing challenges.
August 2023     37
 6 BENEFITS
OF AR IN
MANUFACTURING

In addition to allowing workers to be more effective

and faster in each of their tasks (assembly,
inspection, maintenance), an AR solution will enable
them to be more efficient by optimizing processes
and providing digital instructions for operators.
(Courtesy: DELMIA)

38     gearsolutions.com
Augmented reality is becoming a growing and useful
tool to maintain a more efficient shop floor during the
manufacturing process.
By WENDY MLYNAREK
M
anufacturers are increasingly incorporating
augmented reality in their digital transforma-
tion strategy. Augmented reality provides a
multiplier effect for improving the efficiency
and quality of production and inspection processes.
Defect detection assistance, improved produc-
tion rate, increased safety for the factory and teams,
increased productivity, reduced cycle times, and, above
all, reduced costs: The benefits are numerous.
AR allows the industrial sector to gain effectiveness
and efficiency while reducing errors and the additional
costs generated, but it does not stop there.
Here is a closer look at some of the main benefits of
augmented reality in manufacturing:
1 INCREASING PRODUCTIVITY
THROUGH AUGMENTED REALITY
AR is a solution whose effectiveness and value to the
industry are more proven than ever to increase indus-
trial productivity. When used in factory and produc-
tion processes, there are many gains to be made in a
quest for operational excellence.
In addition to allowing workers to be more effective
and faster in each of their tasks (assembly, inspection,
maintenance), such a solution will enable them to be
more efficient by optimizing processes and providing
digital instructions for operators.
A company’s teams can identify non-conformities
faster and drastically reduce errors and related costs.
Operations are performed correctly by having the right
information in the right place at the right time and
assigned to the right person.
To summarize, whatever the industrial perfor-
mance, it will be optimized thanks to:
 Faster learning curve for new operators.
 Reduction of inspection time (DELMIA Augmented
Experience provides up to 84 percent reduction of
inspection time measured at our customers).
 Reduction of cycle times and reporting.
 Automatically updated reports and documenta-
tion.
 Better traceability.
2 IMPROVING QUALITY THROUGH AR
The detection and reduction of non-conformities are
one of the main objectives of the teams in charge
of inspection and quality. The slightest error can be
extremely costly and can lead to a series of time-con-
suming corrective actions, such as:
 Correctly identified defects.
 New production runs.
 Several additional quality controls.
 Possible additional logistical costs.
 Generate dissatisfaction for end customers.
A detected non-conformity or error often implies
more time to devote to the handled part, which can
even go as far as stopping the production to identify
and resolve the problem. The challenge is to detect
errors as early as possible in the process to avoid late
detection and the need to stop production. This can
be a major challenge, especially when an operational
excellence strategy is needed.
An augmented reality solution allows workers to
anticipate these errors. With an AR tool, quality con-
trol information is contextualized and localized to
simplify the inspection process. Operators are guided
through each inspection point using 3D data imported
directly into the field and superimposed on the part to
be inspected throughout the manufacturing process.
This capability supports efficient validation of product
conformity. In addition, errors are precisely localized,
allowing the proper corrective and repair actions to
be applied. DELMIA Augmented Experience solutions
are already helping many industrial customers identify
and efficiently report production defects.
But the best way to reduce quality problems is to
avoid assembly errors in advance. AR effectively guides
the operator to achieve “first-time right” via the con-
textualization of work instructions and their display
in the field, making them intelligible.
3 CONNECTING THE FIELD WITH NEW
DIGITAL CAPABILITY
What if the augmented operator was the connection
point that could reconcile the real and virtual worlds?
Displaying digital data from the design teams on the
shop floor allows the operator to interact with the data.
AR becomes the link to creating a tangible connection
between the virtual (and all the digital information
from the engineering office), with the real, meaning
the operations happening on the field.
Implementing an augmented reality solution, espe-
cially if the chosen technology offers integration capa-
bilities with the existing systems (MES, for example),
may be the answer to the digital gap between V + R.
4 SUPPORTING THE FUTURE OPERATOR
BY BOOSTING SKILLS DEVELOPMENT
Integrating AR solutions in the factory can positively
affect team training. The simple fact of using augment-
ed reality contributes to an operator’s training and
increases their skills. Using digital work instructions
August 2023     39
Digital continuity can be possible with augmented reality. (Courtesy: DELMIA)
Integrating AR solutions in the factory
can positively affect team training.
The simple fact of using augmented
reality contributes to an operator’s
training and increases their skills.
projected in the field or visualized through a tablet or augmented
reality glasses, field teams receive the right information at the right
time and become operational more quickly.
It is proven that using a virtual world facilitates the assimilation
of information communicated and its application in the field. This
way, operators develop much more intuitive gestures allowing them
to become more autonomous and to respond well to possible issues.
In addition, it also facilitates the memorization of the information
transmitted to a company’s teams.
Integrating an augmented reality solution fits perfectly into a
training strategy. It facilitates the transmission of knowledge within
the company and develops operators’ autonomy more quickly, thanks
to its more intuitive content.
5 PROVIDING A SAFER AND MORE
COMFORTABLE WORK ENVIRONMENT
Augmented reality technologies can also improve a factory’s safety
and comfort. Complex assembly operations or maintenance actions
provide significant support, consider many risk factors, and detail
faults with better accuracy than any other resource (documentation
or technicians).
 Comfort: The various hardware configurations compatible with
augmented reality solutions allow workers to adapt to the worksta-
40     gearsolutions.com
tion. The variety of hardware enables them to work hands-free and
avoid numerous return trips to the office. A savings of time and
energy that also provides comfort for a company’s teams.
 Technician safety: Operators are better guided and accompa-
nied step-by-step with alerts displayed in AR at the proper process
moment.
As a result, the risk of human or technical errors is reduced, and
field teams can better understand the company’s processes.
6 OPTIMIZE DOCUMENTATION, TRACEABILITY,
AND REPORTING
Augmented reality supports a solution for better industrial traceabil-
ity. Getting the right information at the right place at the right time
can be complex. Manufacturers need to be aware of a lack or break
in collecting field data and documentation that is not up-to-date and
too difficult to use.
Using augmented reality in the plant can positively affect trace-
ability. A good AR solution offers “as-built” data collection capabilities
in the field with automated reporting, which provides full visibility
into the assembly and inspection processes throughout the produc-
tion and distribution chain.
We help industries optimize their traceability with innovative digi-
tal solutions that provide automatic data collection directly from the
field following quality control. With such a solution’s capabilities,
you can conduct documented inspections for internal traceability
purposes and better communication with your customers.
AR HAS MANY ADVANTAGES IN INDUSTRY
 Augmented reality helps achieve operational excellence (getting
it right the first time).
 AR solutions bring rapid ROI by improving quality, deadlines,
productivity, etc.
 AR improves traceability and contributes to the collection of data
Augmented reality technologies can improve a factory’s safety and comfort. (Courtesy: DELMIA)

that will feed the digital twin. bly and inspection times.
 It encourages operator-skill development. With augmented reality, performance can be optimized consider-
 It contributes to the reduction of cycle times by reducing assem- ably while reinforcing manufacturing processes.

ABOUT THE AUTHOR

Wendy Mlynarek is strategic business development director at Dassault Systèmes for the DELMIA brand, supporting aerospace and defense
and the virtual twin experience marketing for manufacturing operations program. She has more than 25 years of experience in marketing
manufacturing solutions globally.

ARE YOU MAXIMIZING YOUR EXPOSURE?

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JOIN THE GEAR SOLUTIONS
industry with a storefront in the Gear
COMMUNITY Solutions Community.
FOR ONLY
$
350
PER YEAR
Storefronts paint a portrait of your company
with a 500-word description and include
your logo, 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 dave@gearsolutions.com.
Dave Gomez – national sales manager
800.366.2185 x 207

August 2023     41
COMPANY HORN USA
PROFILE

COMBINING
CUTTING-EDGE
TECHNOLOGY,
PERFORMANCE,
AND RELIABILITY

HORN supplies gear production solutions

for 5-axis milling, broaching, gear
hobbing, and skiving. (Courtesy: HORN)

42     gearsolutions.com
Horn USA offers a wide array of cutting tools
that can be used wherever maximum precision
is required: From the automotive industry and
aerospace technology to the jewelry industry
and medical technology.
By KENNETH CARTER, Gear Solutions editor

W
hen it comes to manufacturing gears, the the human capital within a company, according to
bottom line often boils down to precision Csizmar. HORN employs a global team with extensive
— precision in cutting, precision in milling, hands-on experience with gear machining and the
precision in skiving. Whatever the process, design of gear cutting tooling. It leverages knowledge
precision is key. from numerous applications around the globe and
Horn USA, a subsidiary of Paul Horn GmbH, contin- trains the internal team regularly on the latest pro-
ues to advance its goals of producing the best and most cesses and developments.
precise gear tooling available to the industry. “HORN has also invested heavily into software to
“HORN is exceptional at creating precise forms assure the quality and precision of the gear form,” he
between flanks,” said Mike Csizmar, national sales said. “In some cases, we have helped customers find
manager for Horn USA. “We work to microns, and our errors on their prints and specifications using our
form tolerances are accurate and repeatable. We utilize software.”
the most advanced equipment available
combined with our own software solu-
tions to generate gear tooling. HORN
also coordinates with cutting edge
machine tool partners to execute the
design with the highest measurement
accuracy.”
Gear processes available from HORN
include milling, broaching, skiving,
deburring, and finishing, according to
Csizmar.
“Our philosophy is to engineer a solu-
tion to produce the gear form correctly
the first time,” he said. “HORN has solu-
tions from module 0.5 up to module 30.
The indexable and solid tools we manu-
facture cover spur gears, shaft hub con- Gear processes available from HORN include milling, broaching, skiving, deburring,
and finishing. (Courtesy: HORN)
nections, worms, bevels, pinions, and
custom forms. HORN supplies gear pro-
duction solutions for 5-axis milling, broaching, gear CONSULTIVE SELLING
hobbing, and skiving.” Csizmar emphasized HORN strongly advocates consul-
tive selling as a means to achieve its objectives.
STRONG PARTNERSHIPS As an example, Csizmar mentioned a customer that
As with all the tooling HORN produces, it strives to was outsourcing the splining of shafts. HORN devel-
partner with its customers and deliver the highest pos- oped a solution that allowed the customer to produce
sible value, according to Csizmar. HORN’s cooperation the spline in the same machine in one set-up, thus
doesn’t stop with the end user. It also works with top eliminating scrap and weeks of lead time.
OEMs to develop gear-manufacturing processes for a “By partnering with our customer and helping
complete solution, which allows for a more complete them improve their process, they have grown from a
picture of the process, the limitations, and dimension- three-machine shop to over 20 CNCs,” he said.
al requirements.
NEW U.S. FACILITY
DEVELOPING NEW TECHNIQUES As Horn USA has continued to grow its presence in
The key to successful gear machining starts with North America, that growth is reflected in the com-

August 2023     43
Horn USA, a subsidiary of Paul Horn GmbH, continues to advance its goals of producing the best and most precise gear tooling available to the industry. (Courtesy: HORN)

pany’s new facility. The 118,403-square-foot manufacturing center

opened in 2020 and supports the North American market. The facil-
ity provides standard and made-to-order solutions for all types of
machining processes and customer applications.
HORN also offers comprehensive training for internal staff and
external customers with meeting and training rooms designed for a
flexibility that goes beyond a standard classroom setting.
“The Horn USA facility definitely is a proud testament to the long,
prosperous road HORN has traveled since being incorporated in the
U.S. in 1997,” Csizmar said. “Since 1997, we have been blessed with
steady growth from one grinder in 2000 to over 36 grinders pres-
ently. This year we have also added HiPiMS coating units to better
serve our market with shorter leads times and more advanced coating
possibilities.”

MORE EXPANSION PLANS

Despite the wide array of gear-manufacturing processes already avail-
able, Csizmar said HORN remains deeply committed to exploring
further avenues for expanding its capabilities. Expanding capabili-
ties will only make it easier for HORN to take on the challenges gear
manufacturers will face in the coming years.
As gear manufacturing evolves with fewer automotive transmis-
sions and more electric drives, HORN is positioning itself to meet
that need. That will mean bringing more manufacturing capability
to HORN’s U.S. facility, including reconditioning of skiving tools.
HORN employs a global team with extensive hands-on experience with gear
“Right now, portions of our gear program are still made in machining and the design of gear cutting tooling. (Courtesy: HORN)
Germany, but we are increasing our ability to manufacture and ser-
vice more gear products here,” Csizmar said.
HORN’s current product line, as well as its plans for the future, will
help ensure the company is positioned to be a value-added supplier
MORE INFO www.horn-group.com/us
in the world of gears for years to come.

44     gearsolutions.com
YOU’VE GOT THE PRODUCTS.
YOU’VE GOT THE SERVICES.
NOW, LET US SHARE YOUR STORY.
Gear Solutions wants to make sure the best
possible audience knows your company.
Through our print, online, and social media
presence, our experienced staff can get your
message to an industry that wants to know
what you can do.

To learn more, contact national sales manager

Dave Gomez at dave@gearsolutions.com
or call 800.366.2185 ext. 207

August 2023     45
 PRODUCT
SHOWCASE
Fixtureworks nut runner clamps for robotic and automated clamping. (Courtesy: Fixtureworks)
Fixtureworks nut runner
clamps for robotic and
automated clamping
Fixtureworks®, a leading North American
manufacturer and supplier of clamps, fix-
turing accessories, machine tool components,
and rollers and bumpers, now offers a line of
nut runner clamps in both swing and block
pull versions that can provide robotic clamp-
ing, automated clamping, and unclamping
on automated and robotic production lines.
A nut runner is a member of the industrial
torque wrench family — a series of tools used
to tighten nuts, bolts, and screws in situa-
tions where torque is crucial. Unlike stan-
dard wrenches, torque wrenches can apply
a defined level of torque to a bolt.
Unlike hydraulic solutions, Fixtureworks
nut runner clamps provide mechanical
clamping without the need for hydraulic pip-
ing. This simplifies fixture design and main-
tenance, shortens preparation time, and low-
ers costs. They are equipped with a hex head
for automated clamping and unclamping.
Spiral-acting swing clamps and block pull
clamp types are available. They offer the high
clamping force needed on machining and
assembly lines. They can provide rigid and
easy mounting to the plate and provide no
tool interference for top surface machining.
The swing clamps, with clamping force
46     gearsolutions.com
NEW PRODUCTS, TRENDS, SERVICES & DEVELOPMENTS
up to 1,350 pounds, swing into position, then
clamp straight down onto the workpiece for
direct downward pressure. When releasing
the clamp, the arm swings out 90 degrees
for easy removal and placement of the work-
piece. The internal spiral groove forces posi-
tive clamp arm rotation both in the clamping
and unclamping motions. These clamps are
designed to be used in robotized production
lines where robots use nut runners. A torque-
settable impact wrench may also be used to
operate these clamps.
Block pull clamps, with clamping force
up to 2,700 lb., provide very quick and secure
fastening and are ideal for 5-axis machining.
They consist of a clamp base used with clamp-
ing screws. Block pull clamps mount under a
workpiece, which allows the surface that will
be machined to be accessible to the cutting
tool. In addition to tightening with a wrench,
this clamp can be operated with nut runner
for automation and impact wrench for lower
workload. Clamping screws are used with
block pull clamps.
In addition to nut runner clamps,
Fixtureworks offers quick change pneumat-
ic clamping fasteners, quick action sliding
locks spring plunger clamps, handle and
levers, knobs and grips, equipment han-
dles, hand wheels and cranks, hinges and
latches, leveling supports, industrial rubber
bumpers, stops and wheels, fixture clamps,
clamping locating systems, work position-
ing elements, vises, grippers, and mechani-
cal linear actuators.
MORE INFO www.fixtureworks.com
GF Machining Solutions
unveils new CUT F
Series of EDMs
With the perfect balance of precision
and productivity in mind, GF Machining
Solutions launched the first model of its
new CUT F Series of wire electrical discharge
machines (EDMs) at the grand opening of the
company’s Medical Center of Competence. As
the first of its kind, the new center provides
manufacturers supplying the medical indus-
try with comprehensive applications support
along with world-class production technolo-
gies, one of which is EDM.
Stemming from more than 100 years
of EDM experience, the new CUT F 600
is designed for ease of use and f lexibil-
ity, thanks to many of the company’s most
innovative technologies. These include the
Uniqua control, ISPS and iWire intelligent
functions, and RFID Smart Wire system
along with design enhancements for thermal
stabilization, vibration control, and machine
movement precision.
The CUT F 600’s intuitive Uniqua human/
machine interface (HMI) delivers optimal
functionality and ergonomics with a 19-inch
vertical touchscreen, full keyboard, and
mouse. For the utmost compatibility, Uniqua
supports legacy file types from various EDM
manufacturers, and with offline and at-the-
machine programming, ISO-based func-
tionality and object-oriented programming,
Uniqua provides a powerful graphic tool
with integrated CAM and also ensures com-
patibility with major CAD/CAM programs.
The iWire function of the CUT F 600 auto-
matically identifies and adapts wire speed to
changing erosion height conditions during
the wire EDM process. This capability elimi-
nates wire breakage while reducing overall
wire consumption per job, in some instances
by as much as 29 percent. The iWire func-
tion works in tandem with the company’s
Intelligent Spark Protection System (ISPS),
both of which are part of the Uniqua control.
 ANCA launches MX7
ULTRA to produce highest
accuracy cutting tools
ANCA’s new MX7 ULTRA can manufacture
large volumes of endmills and other cutting
tools of the highest accuracy and quality. The
minute size of a micron is beyond the human
eye, but in becoming even more precise and
moving from micrometers to nanometers,
ANCA will offer the highest accuracy and
quality in a cutting tool in the market. New
software, hardware, and design features
are combined to make significant advances
in surface finish, accuracy, and controlled
runout, to deliver batch consistency from
the first ground tool to the thousandth. The
machine will be displayed September 9-14 at
IMTA Booth #237406.
The MX7 ULTRA includes:
 Nanometer control system.
 New servo control algorithm for smooth
motion.
 System and mechanical upgrades
enhance stiffness and rigidity.
 In-process measuring, balancing, and
runout compensation for consistent accuracy.
GF Machining Solutions’ new CUT F 600 is designed  Motor Temperature Control (MTC) –
for ease of use and flexibility, thanks to many of the compensation for thermal expansion on the
company’s most innovative technologies. (Courtesy:
GFMS)

iWire can not only recognize exactly CUSTOM ENGINEERING,

where the sparks of a wire EDM are happen-
PROTOTYPE WORK, PRECISION
MACHINING, ASSEMBLIES AND
ing during the process, it can also measure
and identify the position of each spark along
the length of an EDM’s wire. Knowing the
exact location of a spark allows iWire to auto- STANDARD COMPONENTS
matically adapt the wire spool speed accord-
ingly. Such capability reduces the chances of Gears, pulleys,
wire breakage during unattended operations shafts, bearings,
when EDMing parts with steps and other couplings,
features that vary the erosion height — the fasteners,
length of the actual surface areas where the
custom gear
wire is eroding/cutting.
Also available with the CUT F Series
boxes
machines is the RFID SMART wire spool tech-
nology. The system stores wire characteris-
tics as well as other traceability-related data.
For increased precision machine move-
ment, vibration control, and overall process
stability, the CUT F Series machines feature
several enhanced design elements. One of ISO9001:2015 & AS9100D,
which is the cooling of axis optical encoders ITAR Registered, NIST.SP800-171R1,
using the work tank and the dielectric fluid. Trace Certified,
The other design change is the incorpora-
Class 100 clean room Gears 2mm to 500mm
tion of higher accuracy machine ball screws
that improve both positioning accuracy and
smoothness. Nordex.com I Sales@nordex.com I Eng@nordex.com
800-243-0986 I 203-775-4877
MORE INFO www.gfms.com
August 2023     47
PRODUCT
SHOWCASE
Introducing one nanometer axis resolution, ANCA’s new MX7 ULTRA machine’s performance can maintain
less than ±0.002mm line form accuracy of any profile which includes ballnose and corner radius endmills.
(Courtesy: ANCA)
grinding spindle.
 Specialist training support in how to
grind industry leading cutting tools.
“The MX7 ULTRA is a significant develop-
ment in precision machine design and will
change the industry expectations for accu-
racy and tool life,” said Pat Boland, ANCA
co-founder. “Achieving these outstanding
results has only been possible because of our
extensive experience working with custom-
ers to manufacture the highest quality cut-
ting tools over many years. At ANCA, we are
always designing and innovating to find bet-
ter customer solutions and I am very proud of
the ANCA team that has developed the MX7
ULTRA.”
“The ULTRA machine is truly market-
changing,” said Thomson Mathew, ANCA
product manager for the MX series and
software products. “It is the culmination
of ANCA’s elite technology, deep industry
knowledge, and customer experience in
grinding.”
Unlike its competitors, ANCA is vertically
integrated. This provides a significant advan-
tage as it means ANCA teams can develop and
manufacture their own machines from base
to canopy — including controls and drive sys-
tems, design and simulation software, and
even machine-monitoring software. Owning
all the technology means engineers and
designers can consider the entire machine
as a single system when developing new solu-
tions.
“We wanted to create technology that
48     gearsolutions.com
could produce premium cutting tools that
are above the current market standard in
both accuracy and tool life,” Mathew said.
“We introduced nanometer resolution into
our axis, which is new to the cutting tool
market. The result is a perfect example of
ANCA’s vertical integration capabilities as
we have the in-house ability to fine tune or
develop the new algorithms for our drives to
make this happen.
“Cutting tools like ballnose, corner radi-
us, barrel shape ballnose, and double cor-
ner radius endmills are used widely across
industries including diemold, aerospace, and
power generation. The surface finish qual-
ity, accuracy and runout are critical for the
performance and cutting life in all applica-
tions — so our customers want a guarantee
that their first tool will be exactly the same
as the hundredth, or thousandth. The MX7
ULTRA can produce high quality cutting
tools to suit all customer needs to satisfy all
industry types.”
MX7 ULTRA performance highlights:
 Greater control for the velocity and
acceleration or deceleration along with
machine jerk limits.
 ULTRA-fast response to internal or
external disturbances.
 Better cycle time and higher productiv-
ity of high-quality cutting tools.
 Reduces setup times and scrap.
 Increased wheel life and better-quality
tools.
 Consistency in finished tool quality.
 Consistent spindle thermal stability.
 Post grinding processes.
MORE INFO www.anca.com
Weiler Abrasives
introduces Tiger 2.0
cutting, grinding wheels
Weiler Abrasives, a leading provider of
abrasives, power brushes and maintenance
products for surface conditioning, released
the next evolution of abrasives — Tiger 2.0
zirconia alumina and aluminum oxide cut-
ting, grinding, and combo wheels. Designed
for demanding metal fabrication industries
such as shipbuilding, pressure vessel, and
heavy equipment fabrication, these abrasives
help cut through inefficiencies, safety issues,
and labor shortages that prevent companies
from doing their best work.
“We understand that our customers’ pro-
duction environments are ever-changing
and many are challenged with doing more
work with less labor,” said Tony Hufford, cat-
egory manager Metal Fabrication at Weiler
Abrasives. “We listened to their feedback to
determine what they want and need in their
abrasives. The result is wheels that offer fast
cut-rates with extended life that we devel-
oped through countless hours of trials and
validation to provide the best product to
market.”
In addition to offering fast cutting speed,
Tiger 2.0 wheels last up to 40 percent longer
to increase efficiency in operations’ cutting
and grinding applications. The wheels fea-
ture an award-winning blotter design that
includes an industry-first, patent-pending
Optimum Use Line. The line is a visual indi-
cator that helps the operator use the wheel to
its full life. This innovation reduces change-
overs, allowing for greater productivity while
also reducing waste and abrasive spend. In
some cases, users experience three times
more efficiency than with their previous
abrasives.
Tiger 2.0 grinding wheels feature anti-
chipping technology, an advanced bond
formulation that reduces uneven edge wear
and chipping to improve safety and the user
experience, and extend wheel life.
All of the wheels deliver smooth, predict-
able cutting and grinding, making the work
safer. The addition of a QR code on the wheels
makes it convenient for operators to access
crucial safety information where and when
they need it.
 Formerly Gear Expo

is
OCTOBER 17–19, 2023 DETROIT, MI
Huntington Place Convention Center

Attending Motion + Power Technology Expo puts you right in the center
of the power transmission supply chain.

• Keep up with the latest R&D and gearing

innovation at the AGMA Fall Technical Meeting
• Network with leading professionals at the
Opening Night Welcome Reception, free to all
attendees
• Be empowered and connected at the Women
Register Today!
in Manufacturing and Engineering Breakfast
• Gather with executives at the International
Power Transmission Summit
MOTIONPOWEREXPO.COM/GS
• Advance your knowledge during one of the
many in-depth education sessions
• See how AGMA is leading the way at the AGMA
Electric Vehicle Technology Town Hall

August 2023     49
PRODUCT
SHOWCASE
Weiler’s Tiger 2.0 zirconia alumina and aluminum oxide cutting, grinding, and combo wheels are designed to
help operators produce their best work. (Courtesy: Weiler Abrasives)
Weiler Abrasives took today’s labor short-
ages into consideration when formulating
the Tiger 2.0 wheels. The wheels produce
consistent results among different users to
reduce training time and minimize rework.
The wheels also make cutting and grinding
easier to lessen operator fatigue and improve
employee retention.
Tiger 2.0 wheels are available in Type 1,
Type 27, and Type 28 options. These wheels
range in size from four to nine inches and are
intended for use on portable angle grinders.
MORE INFO www.weilerabrasives.com/tiger-2.0
Rego-Fix brings
innovative tooling
solutions to SOUTHTEC
Along with its extremely popular powRgrip
(PG) tool holding system, Rego-Fix will show-
case several other tooling innovations dur-
ing SOUTHTEC in Booth #416 October 24-26.
Those innovations include the company’s
expanding line of precision metrology prod-
ucts and recent additions to the powRgrip
family. Among the additions are the new
PG48 along with MQL, CoolBore, and grind-
ing PG collets.
The company’s PG 48 tool setting concept
expands the PG line to 1.5-inch (38.1 mm)
tools and includes a groundbreaking new
tool setting unit that extends the capabilities
of the company’s clamping units.
Current PG tool setting units — including
the time-tested PGU 9500 and the enhanced
new PGU 9800 — use up to nine tons of clamp-
ing pressure to secure a tool in less than 10
seconds. To handle larger tools, the all-new PG
50     gearsolutions.com
The Rego-Fix ergonomic 3D-EdgeMaster centering
devices shorten setup time and ensure part accuracy
in an IP 67-compliant shockproof and splashproof
design for demanding applications. (Courtesy: Rego-
Fix)
48 will rely on a specially made PGU machine
that can use up to 16 tons of pressure.
Like all Rego-Fix PG tool setting tech-
nologies, the new PG 48 tool setter will use
neither heat nor hydraulics, so tools will be
ready for use immediately after the clamp-
ing cycle concludes. The Rego-Fix clamping
methodology avoids the limitations and tool-
life compromises of other systems.
Rego-Fix minimum quantity lubrication
PG-MQL collets apply a light spray of an air
and oil mixture directly to cutting zones.
This spray not only lubricates cutting tools
to extend their working lives, but it also
minimizes coolant use to reduce costs and
effectively evacuates chips to prevent scrap
and ensure quality part surface finishes.
For the highest gripping force of any Rego-
Fix coolant collets, form-fit PG CoolBore
Collets (PG-CB) deliver high-pressure periph-
eral coolant for optimized chip removal in
medium to high-performance applications.
These collets change out quickly with other
powRgrip coolant collets and provide maxi-
mum coolant output pressure for PG 25
(including short collets) and PG 32.
For various grinding applications, Rego-
Fix now offers its PG ER collets for clamping
grinding pins. The line of collets ensures
runout of less than three microns at 3xD and
provides exceptional vibration damping for
superior surface finishes.
To add Rego-Fix precision to setup mea-
surements, ergonomic 3D-EdgeMaster cen-
tering devices shorten setup time and ensure
part accuracy in an IP 67-compliant shock-
proof and splashproof design for demand-
ing applications. Designed to set zero points,
probe reference edges and workpieces,
calibrate measuring paths, center machine
axes, and determine bore centers, these new
devices feature repeating accuracy of ≤0.01
mm. 3D-EdgeMaster is available in metric
and inch sizes and with short or long probes,
all individually serial numbered, with fully
traceable inspection and performance certi-
fication for demanding industries.
Shops can minimize spindle-damage
risks and maximize process reliability with
MasterBar test arbors, available with HSK,
steep-taper ST, BT, and CAT interfaces for
correct machine tool setup and spindle pre-
cision with every use. Ground to the same
exacting specifications as Rego-Fix toolhold-
ing products and supplied with full techni-
cal certification, these devices check spindle
runout, spindle and arbor alignment, and
arbor length to boost part quality, reduce
scrap, and recheck for changes in runout and
parallelism after a crash.
MORE INFO www.regousa.com
 32ND HEAT TREATING SOCIETY CONFERENCE AND EXHIBITION
OCTOBER 17–19, 2023 | HUNTINGTON PLACE | DETROIT, MICHIGAN

DRIVING THE FUTURE OF THERMAL PROCESSING

REGISTRATION NOW OPEN!

Heat Treat is the premier conference and expo for heat treating
professionals, attracting international innovators, researchers,
influencers, and decision makers from around the globe.
Co-located with IMAT 2023 and Motion + Power Technology Expo, Heat Treat attendees can
access the POWER of three events in ONE location, offering MORE content, MORE attendees,
MORE networking, and MORE ROI, including:
• 450 Technical Presentations, Keynotes, and Special Sessions
• 5000 Attendees
• 400 Exhibitors
Don’t miss out on attending the largest conference and expo in North America dedicated to
heat treating!

ORGANIZED BY: CO-LOCATED WITH:

Register today!

heattreatevent.org August 2023     51

PRODUCT
SHOWCASE
FOBA introduces
ultrashort pulse
laser marker
FOBA’s new F.0100-ir marking system cre-
ates deep black markings on medical stain-
less steel, titanium, or plastics. Its adjustable
pulse width and its 10 watts laser power
enable accurate results on various surfaces.
In combination with FOBA’s validation-
ready process solution, the F.0100-ir provides
advantages especially for medical device
manufacturers.
The ultrashort pulse laser marks in the
deepest matte and non-reflective black with-
out generating significant heat input on the
workpiece. Even through further process-
ing steps, such as passivation, the marking
remains reliably legible and corrosion resis-
tant. Due to the very short pulses down to
the femtosecond range, in combination with
high pulse energies, the system marks vari-
ous stainless steels, titanium, and a variety
of plastics.
When developing its ultrashort pulse
laser system, FOBA placed particular empha-
sis on its ability to be integrated into the
Learn more at cleanpower.org
52     gearsolutions.com
F.0100-ir marking system pro-
vides a wide range of applica-
bility, high precision, and out-
standing process stability.
“The laser head is so com-
pact that we can integrate it
into our M-Series marking
workstations. And that is
often a requirement with our
customers. Since the system is
FOBA F.0100-ir ultrashort pulse laser marking system with its laser air-cooled and uses hardly any
control and supply units. (Courtesy: FOBA)
consumables, it requires little
maintenance. In addition, the
proven FOBA workflow. high marking speed in combination with
“For our customers, it is of course crucial FOBA’s established camera and software solu-
that our lasers achieve consistently reliable tions enable lean and efficient part manufac-
marking results,” said FOBA director prod- turing.”
uct management Philipp Febel. “But they also FOBA offers interested users sample
trust that the entire process is highly depend- markings with the new USP marking system.
able, and a new marking system has to keep Marking applications from medical device
up with that.” manufacturing, automotive component pro-
The integration of a capable, compact, and duction, or electronics are suitable. Materials
very flexible laser source was the top priority that are usually marked with other wave-
during product development. lengths such as UV can also be considered.
“Our laser system offers adjustable pulse Detailed advice on the best possible marking
widths for specific material requirements,” configuration will be part of the service.
Febel said. “This is not a matter of course in
the ultrashort range. As a result, the FOBA MORE INFO www.fobalaser.com
American Clean Power is the
voice of the clean power industry
that is powering America’s future,
providing cost-effective solutions
to the climate crisis while creating
jobs, spurring massive investment
in the U.S. economy and driving
high-tech innovation across the
nation. We are uniting the power
of America’s renewable energy
industry to advance our shared
goals and to transform the U.S.
power grid to a low-cost, reliable
and renewable power system.
 GET YOUR SOURCE FOR
GEAR INDUSTRY NEWS FREE

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August 2023     53
 MARKET
PLACE Performance
Dependability
Contact Gear Solutions SPECIALISTS IN PRECISION Value
at 800-366-2185 to CONTROLLED HEAT TREATING
• GAS CARBURIZE & NITRIDE
feature your business • PRESS/PLUG/ROLL QUENCH
in the Marketplace! • NEUTRAL & PRECIPITATION HARDEN
• VACUUM CARBURIZE
• SUPPLY CHAIN MANAGEMENT

PERFORMANCE ~ INTEGRITY ~ IMPROVEMENT

• CERTIFIED WOMAN-OWNED BUSINESS
• NADCAP ACCREDITED
• ISO 9001:2015 • AS9100D • IATF 16949:2016

www.sst.net • 586.293.5355 • info@sst.net

1.866.HOB.TOOL
w w w . h o b s o u r c e . c o m

#3 Fellows
Gear Shaper
with Fanuc 4
Axis CNC

SERVICING FELLOWS GEAR SHAPERS

SERVICING FELLOWS
The Voice of Manufacturing On Site Service: Emergency & Scheduled
GEAR SHAPERS
Technical Support: Via Telephone, Fax or E-mail
every Tuesday On SiteOperator,
Training: Service:Set-up
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& Maintenance (Electrical
www.mfgtalkradio.com & Mechanical)
Technical Support: Via Telephone or E-mail
Preventive Maintence Plan: Customized to Your Needs
Training:
Parts: Operator,
New and/or UsedSet-up & Maintenance
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ts - Counters, Servo Controllers, or Single and
with Multiple Axis CNC
Preventive Maintenance Plan: Customized
Lewis Weiss Hydrostatic Guides: Repair Service or Purchase New
to Your Needs
and Allen
Parts:Adams
New and/or Used
Tim Grady SHAPER SERVICES, Inc.
ALLEN ADAMS SHAPER SERVICES, INC.
Retrofits: Counters, Servo Controllers, or
174 Innovation Drive N. 174 Innovation Drive • North Clarendon, VT 05759
Single and Multiple Axis CNC
Clarendon, VT 05759 Telephone: 802-226-7891
Hydrostatic
Telephone: and Mechanical Guides: Repair
802-226-7891 E-mail: shaperservices@shaperservices.com
Service
E-mail: or Purchase New
shaperservices@sharperservices.com Website: www.shaperservices.com
Website: www.sharperservices.com

HOB & SKIVE CUTTER SHARPENING BY PROFESSIONALS…

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FOR THE PROFESSIONAL GEAR MANUFACTURER. Advertise with us in print and online, and you can reach
• HOB SHARPENING over 45,000 potential readers – many who are key
• SKIVING & SHAPER CUTTER decision makers at their companies.
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216-642-5900 To learn more, contact national sales manager Dave Gomez
Fax: 216-642-8837 • Email: gallen@gallenco.com at dave@gearsolutions.com or call 800.366.2185 ext. 207
5755 Canal Road, Valley View, OH 44125

54     gearsolutions.com
ADVERTISER
INDEX
CONTENTS PAGE NO. www.toolink-eng.com
303-776-6212
303-776-6212
www.toolink-eng.com
AGMA (American Gear Manufacturers Association...................................49

Allen Adams Shaper Services.................................................................54

All Metals & Forge Group.................................................................. 3, 54

Precision products
American Clean Power...........................................................................52
for gear and rotor
ASM International.................................................................................51
manufacturing
Atlas Bronze.........................................................................................13 Precision Products for Gear and Rotor Manufac

Avers Machine and Gear........................................................................11

Hydraulic & Mechanical
Hydraulic &• Arbors
B&R Machine and Gear Corp.................................................................15
Mechanical•• Chucks
Fixtures
Broach Masters Inc.................................................................................5 Clamping • Special Flanges

Excel Gear Inc......................................................................................17 __________________________________________________________________

CNC Gear Cutting Mach
• Hobbers
Forest City Gear...................................................................................IFC
• Shapers
• VTL’s (vertical turning la
Hobsource............................................................................................54

CNC Gear & Thread Gr

Index Technologies Inc..........................................................................54
CNC Gear Cutting Machines
• Gear Flank – Profile
• Gear Flank – Continuous
Involute Gear & Machine.......................................................................16 • Spiral Bevel Cutters & G
• External & Internal Threa
KHK-USA.............................................................................................18

KISSsoft USA LLC................................................................................11 Machine

TendingMachine
– Part Tending – Part
Liebherr..................................................................................................1
Auto-loading
• Compact
• Flexible
CNC-Boxy M

Nidec Machine Tool America................................................................. BC • Economical Design

• Short Run or Lights Ou
__________________________________________________________________
New England Gear...................................................................................7

Nordex.................................................................................................47 Tool Sharpening Machin

• Compact, Flexible, w/Int
OTEC Precision Finishing.......................................................................23 Tool Sharpening Machine•• –Can Sharpen Virtually all
Including Hobs & Shaper
Piselli Enterprises Inc.......................................................................... IBC 5-Axis CNC • Swiss Quality & Precisio
__________________________________________________________________

Platinum Tooling Technologies................................................................14

RHH Inc...............................................................................................13
CNC Gear &
For additional information contact Joe Passalacqua x101, jpasta@toolink-eng.com

Southern Gear & Machine........................................................................9 Thread Grinding

4665 Nautilus Pl. South, Ste 502A, Boulder CO 80301, Phone: 303-776-6212 www.Tooli

Specialty Steel Treating ........................................................................54

Machines

STD Precision Gear & Instrument Inc.....................................................14

Toolink Engineering Inc.........................................................................55

August 2023     55
 Q& A SŁAWOMIR WOŹNIAK
INTERVIEW WITH AN CEO  SECO/ WARWICK GROUP
INDUSTRY INSIDER
“One of the reasons why we, as a company, are involved with a
green transformation is because it is our mission, but it’s also
because we see more customers following in the same direction.”
You recently attended ThermProcess in Dusseldorf. What kind of
reactions to your products did you get from the attendees?
It was quite a good event for us. We had many visitors coming, both
existing customers as well as new ones. They liked what we presented
at our booth very much, especially all the green technologies that can
support our customers while lowering their carbon footprint. What
we see in the market is absolutely related to cost and process improve-
ment, while meeting the new initiatives of green transformation.
We also see this in the heat-treatment industry, which is a heavy
industry and quite conservative in many aspects, especially with cus-
tomers linked with the automotive industry and commercial treaters.
We see more of that trend going in Europe than in the U.S. so far. But
when you consider the current supply chain and the global link of all
the suppliers, sooner or later, they will have to come into this global
trend and meet all the standards.
What are the ecological advantages of vacuum heat treating?
Vacuum heat treatment equipment and vacuum technologies are our
main business lines. The process uses a lower consumption of process
gases, but also a lower consumption of energy since very often the
process takes a shorter time. Thanks to that, we can increase the
overall productivity.
Vacuum furnace compared to, let’s say, gas carburizing equipment
is very flexible, because you can shut it down anytime you don’t need
to use it, and you can switch it on again anytime you like. With gas
carburizing, the equipment needs to be saturated with carburizing
gas, and you have to maintain the carbon potential. Switching to
vacuum is a greener technology, which means close-to-zero emissions,
a lower energy consumption, and lower process gas consumption.
And if you add the possibility to replace the oil quenching with the
high-pressure gas quenching, then you can also eliminate the need
to make a post-processing washing of the oiled parts.
What other technologies can SECO/WARWICK offer that help
reduce the customer’s carbon footprint?
Last year we promoted a new model of furnace. We call it a Pit-LPC —
pit low pressure carburizing furnace — dedicated for heat treatment
and carburizing in the low pressure of large sized gears — especially
for large gears where a thicker effective case depth of the carburiz-
ing layer is needed. The process takes a very long time — practically
counted in hours. We can reduce the process by 50 percent or even
more if we switch to low pressure carburizing. This is a big advantage
to our customers.
We have also developed the next stage of our ZeroFlow® nitriding
process. We call it ZeroFlow Feedback Control, where we can have a
better control of the nitriding process and optimized process time.
Going further, we have implemented 4D Quench® technology. We
just provided this solution to an aviation customer, who is very happy
to use our technology; 4D Quench can replace the press quench-
56     gearsolutions.com
ing process, where you can do the hardening of gears by using the
high-pressure gas quench. We can control the distortion level of the
quenched gears, so the post-processing of machining is not required
nor is washing of the parts, because you’re not using oil.
The 4D Quench is a fairly new development, correct?
This technology was developed some years ago and was originally
dedicated for automotive industry. As a next stage, we started develop-
ing it as a solution for larger and precision gears dedicated to aviation
transmissions like we can find in helicopters and planes. We know it
is far more difficult to control the distortion of the larger diameter of
gears, and we are able to achieve very good results with our advanced
4D Quench technology.
How can going greener help with your customer’s bottom line?
One of the reasons why we, as a company, are involved with a green
transformation is because it is our mission, but it’s also because we
see more customers following in the same direction. They want to
do it because, being a green company, you can serve more customers.
And it is not just that you are getting greener, but you can also save
costs. This is why our customers want to implement green technolo-
gies that can positively affect their bottom line. This is why more
customers are discussing switching to existing processes that use
new green solutions.
What you’re saying is, there was a necessity to become greener,
but in doing so, they discovered they could actually save money?
Yes. If someone is a part of the global supply chain and is following
all the directions given by the European Union (e.g. “Fit for 55 strat-
egy”) along with more international organizations and institutions,
sooner or later they will need to report the direction they’re going
to lower their carbon footprint. This is what our customers are see-
ing: From one side, financial benefits, but from the other side, they
see a new perspective to enter new markets or to simply maintain
existing customers.
What other ecological activities is SECO/WARWICK involved with?
Besides helping our customers through the solutions we provide them,
we are also, as a company, following the same direction. We have
installed the photovoltaic system, we are switching our fleet of cars
to electrical cars or we use the rainwater to water our grass in the
company, just to mention a few of our pro-ecological measures. These
kinds of activities are also showing our associates that we are not only
providing and helping our customers be green, but SECO/WARWICK
as a group is also a green company.
MORE INFO www.secowarwick.com
 1982 Liebherr Model L-652 Gear Hobber, 26.6” max diameter 2-cut,
crowning, upgraded electronics

Mitsubishi Model ST25 CNC 5 axis, guideless

Gear Shaping Machine, control upgrade 2019

2012 Luren Model LFG-8040 CNC Profile Form Gear Grinder with CNC dressing
800mm (31.4”) diameter Fanuc controls

2006 Mitsubishi Model SE25A CNC Gear Shaper Gleason Model 350 GMM CNC Gear Testers, Gleason Model 600 HTL Turbo Lapper,
10” cap w/ autoloading updated software 2016 & Renishaw probes Fanuc 160I-M control new 2000

Pfauter Model P-500 Vertical Gleason Model 24A straight bevel Gleason Models 102 & 2A coniflex gear 1998 Fellows Model 50-8
Gear Hobber, 20” max diameter Coniflex Gear Generator generators, 4.5” pitch diameter, 16 DP Hydrostroke Gear Shaper

325 N Miller Ave Statesville, NC 28677 THE #1 SOURCE FOR USED GEAR MEMBER
704.609.0766 • rich@pisellient.com MACHINERY — AND MORE!
www.pisellient.com Contact us to add your surplus machinery MEMBER
 CF26A
Gear Chamfering Machine

Gear Chamfering with high speed,

precision and efficiency

Removes
End face burrs
Creates
Defined cut chamfer
Fully integrated
Automation
Low Operating Cost
New ChamferX tool -
only from Nidec!

The new CF26A utilizes generating cutting with our special

ChamferX cutting tools, completely eliminating burrs in the tooth
and end face. Using Nidec's cutting-edge tool design simulation
software, specific defined chamfering shapes are created
including tooth root and complete edges up to 1mm or more.

CF26A: the newest member of the Nidec team pro�ides

Nidec Machine Tool America �EGE��A�� �E��A������ at high speed.

Visit ���.ni�ec-�achine����a�e�ica.c��
and contact sales at 2��-756-5017.