0113_Gearsolutions

kapp-niles.com 2870 Wilderness Place | Boulder, CO 80301 p: 303.447.1130 | f: 303.447.1131 | [email protected]

Estate Planning.

Invest in your future. Kapp-Niles machines are more than just an investment. Theyre essential in planning for the future of your estate. Our machines are built for the long haul, so you can pass them down for

generations to come with 97% of our finishing machines still in operation since 1984. Plus, our quality service

and retrofitting capabilities allow you to stay current with changing technologies.

Invest in Kapp-Niles and invest in the future of your business.

KX 500 FLEX is ideal for single piece or series production of external spur or helical gears. Generating grinding or profile grinding, or a combination of both methods may be used.

Indiana Technology & Manufacturing Companies, Inc. (ITAMCO), left to right: Joel D. Neidig - Technology Manager Nobel Neidig - President Gary Neidig - Vice President

Think Big!

Grind Big!

IMTEX Bangalore, India24.01.2013 - 30.01.2013

Whatever you need you can grind it!Liebherr Grinding Technology - No compromises

- choice of gear grinding process technology

- generating grinding and / or profi le grinding

- plated or dressable tools (CBN & corundum)

- multiple gears in one setup

- gear and shaft parts

- advanced software solutions

- different possibilities for noise minimized gear production

Learn more about LIEBHERR Grinding Technology at www.liebherr.com

For the US-market please contact: Liebherr Gear Technology, Inc.

1465 Woodland Drive - Saline, Michigan 48176-1259 - Phone: 734-429-7225

[email protected] - www.liebherr.com

JANUARY 2013 3

Features

28

Company Profile: Kinefac CorporationBy Tim Byrd

A tight-knit family environment and a commitment to excellence has kept this Worcester, MA company ahead of the curve for 50 years.

48

Analysis of Ripple on Noisy GearsBy G. Gravel, Hamburg University of Applied Sciences (HAW)

Ripple analysis provides a tool that aids in the search for the causes of noise and can also be used for production monitoring in the case of known vibration problems.

38

Comparative Corrosion Characteristics of Ground and Superfinished Gear SteelsBy Suren Rao, Doug McPherson, and Gary Sroka

Temperature-controlled corrosion resistance tests performed various steels yields surprising resultsinformation to use in the fight against metal corrosion of gear steels.

Saving Time and Cost for Intricate Gear Peening

By Ruthann Browning

Precision shot peening eliminates the need for masking and reduces distortion. An efficient

upgrade from traditional shot peening, it also reduces labor and process time.

32

JANUARY 2013 5

Departments

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

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

8Trends, data and developments to keep you aware of whats happening with your colleagues in the gear-manufacturing industry around the country and world.

Industry News

55News of products, equipment, and resources from across the manufacturing spectrum that will help propel your company toward success.

Product Showcase

Chuck Chen PRESIDENT

Luren Precision Company, Ltd.68Q&A

24Better flow for cooling media, weight and error reduction, and root optimization are all beneficial results for using powder metal gears.

Materials MatterAnders Flodin

26Gas and electricity are both viable energy sources for heating furnaces, but there are ecomomic and energetic reasons to pick one over the other.

Hot SeatJack Titus

25Accurate thickness, taper, gear blanks, proportions, and other specifications are necessary for maximum gear performance.

Tooth TipsWilliam P. Crosher

61MACHINES

64MARKETPLACE

67ADVERTISER

INDEX

American Gear ManufacturersAssociation

in this section, the premier supporter of gear manufacturing in the united states and beyond shares news of the organizations activities, upcoming educational and training opportunities, technical meetings and seminars, standards development, and the actions of aGma councils and committees.

Resources

JANUARY 2013 | VOLUME 11 / NO. 01

19

A great deal can happen in one year. In 2012, the Gear Solutions staff published a wealth of well-written technical papers, attended numerous gear shows and conventions, presented edi-torial profiles on a multitude of gear companies (big and small), and launched a new column. In the Fall, we debuted Thermal Processing for Gear Solutions, a companion magazine focused specifically on the heat treatment of gears. All year long, we kept pace with a seemingly endless stream of news briefs, product releases, and event dates. This is our continuing effort to our readers and our promise: To provide pertinent content that no one else can in a clear, concise way. 2012 was our best year yet, but were just getting started.

To start the year off, this issue of Gear Solutions offers an abundance of know-how and sound advice in our editorial lineup. Ruthann Browning of Comco, Inc. examines a new development in gear shot peening. An in-depth examination of this intricate process has yielded some time-and-money saving solutions and, most importantly, insight into the extension of gear life. Suren Rao, et. al, of the Gear Research Institute present the results of an experiment involving temperature-controlled corrosion resistance tests in their article, Comparative Corrosion Characteristics of Ground and Superfinished Gear Steels. The before and after pictures of these steels stress the importance of knowing your materials and choosing the right ones for the job. Finally, Gunther Gravel, of Hamburg University of Applied Sciences, gives us his expert opinion on gear inspection, specifically noise analysis. Until now, ripples, or ghost frequencies, could rarely be detected with a gear measuring device. A new evaluation method allows gear manufacturers to identify ripples on the flanks of gears based on the results of normal gear measurement.

Jack Titus gives both sides of the argument for gas-powered heat treatment, a preferred choice in the US, in his Hot Seat column. He takes into account the advancing renewable energies market and its effect on electricity production, and addresses the question: Do the costs outweigh the rewards for gas?

Our Materials Matter column, debuting only two months ago, is quickly becoming a favorite among our readership. Anders Flodin gives us a new set of benefits to using powder metal gear technology, as well as the possibilities using macro design of the gear body. If youre interested in weight and error reduction, along with reducing stress and a number of steps in your pro-cesses, Anders continues his endorsement of PM component manufacturing.

William P. Crosher tells us why more care and attention has to be taken in the selection of the gear blank than with other gear forms in this months Tooth Tips. An extension of his discussion of bevel gears, Mr. Crosher takes a back-to-basics approach to the intricate process of gear design, and how one detail can make all the difference. Well also examine Taiwan-based Luren Presicion Co., Ltd., which works hand-in-hand with local universities, as well as the Taiwanese government, to produce high-quality gear grinders, hob sharpening machines, and software to use in all their interfaces. CEO Chuck Chen was kind enough to give us an inside look at the company in this months Company Q&A. And our company profile spotlights the Kinefac Corporation, based out of Worcester, MA. A world leader in precision metal forming and processing technology, we know youll enjoy this behind-the-scenes look at this internationally renowned manufacturing company.

We hope you are as excited about 2013 as we are. With diligence, determination, and inno-vation, the possibilities in this industry are endless. As always, Gear Solutions welcomes your comments and suggestions, so feel free to contact us anytime. Its great to be here at the start of the New Year, and we feel privileged to ring this one in with you.

Thanks for reading,

Tim Byrd managing editor

Gear Solutions [email protected]

(800) 366-2185 x205

6 gearsolutions.com

Published by Media solutions, inc.P. O. BOx 1987 Pelham, al 35124

(800) 366-2185 (205) 380-1580 fax

David C. CooperPuBlisher

Chad MorrisonassOciate PuBlisher

EDITORLETTERFROM THE

Dav id C . C o operPresident

C had Mor r i s on Vice President

Ter e sa C o operOPeratiOns

Contributing writersWilliam P. crOsherruthann BrOWning

anders flOdinsuren raOgary srOka

dOug mcPhersOnJack titus

gunther graVel

eDitoriALTim Byrd

managing editOr

Stephen SiskassOciate editOr

sALesChad Morrison

assOciate PuBlisher

Michael SellaroliregiOnal sales manager

CirCuLAtionTeresa Cooper

manager

Kassie HugheycOOrdinatOr

Jamie Willettassistant

ArtJeremy Allen

creatiVe directOr

Rebecca AllengraPhic designer

Michele HallgraPhic designer

Coop wants to use this one for the website

Vertical Logo Horizontal Logo

8 gearsolutions.com

INDUSTRYNEWS

Sandvik, a leading global high technol-ogy engineering group, offering advanced products and services in cemented car-bide and high-speed steel cutting tools, materials technology, and mining and construction equipment; and its tooling division, Sandvik Coromant, the worlds leading producer of tools for the metal cutting industry, broke ground Friday, Dec. 3, 2012, on a location neighbor-ing its current U.S. headquarters in Fair Lawn, N.J. The new facility will

serve as Sandviks U.S. head office and a hub for Sandvik Coromants Market Area Americas, a strategic geographi-cal alignment dedicated to increasing synergies between the USA, Canada, Mexico, Argentina, Brazil, Chile and Latin America.

Were proud to reaffirm our roots in New Jersey, said Johan Israelsson, president, Sandvik Coromant, Market Area Americas. Superstorm Sandy dealt a blow to many in this state, but were

not going anywhere. Our new facility will keep Sandvik Coromant headquartered in the same community weve been in for 57 years.

The groundbreaking kicked off the construction of the 108,000 square-foot, state-of-the-art facility that will be designed to meet Leadership in Energy and Environment Design (LEED) stan-dards. The contemporary green design, energy efficient facility will provide gen-eral office space, a Productivity Center

Companies wishing to submit materials for inclusion in Industry News should contact the Managing Editor Tim Byrd at [email protected] accompanied by color images will be given first consideration.

New Products, Trends, Services, and Developments

Sandvik Coromant Breaks Ground in New Jersey

10 gearsolutions.com

and an Aerospace Application Center (AAC).

Serving customers throughout the metalworking field within all major industries, the new Sandvik Coromant Productivity Center will have the capacity to help manufacturers maxi-mize their metal cutting operations by offering a balance of theory-based training courses, technical seminars and hands-on machining demonstra-tions. In addition, the Productivity Center will be staffed with training specialists and machining experts that will educate customers in methods for improving efficiency and productivity in metal cutting.

Sandvik Coromant will also continue its commitment to aerospace with the new AAC at the facility. This state-of-the-art center will focus on projects for machining composite materials or in high temperature and titanium alloys for aero frame structural parts and engine components. The aim is to concentrate specifically on customers who are interested in readdressing their current processes.

A dedicated team of industry spe-cialists will support the customer proj-ects and training at the AAC, which will be fully equipped with the latest machines to develop the most produc-tive processes for aerospace custom-ers.

Both the Productivity Center and Aerospace Application Center will focus on helping American manufac-turers maximize their productivity and profitability through understanding and application of the latest technologies in cutting tools, machine tools and machining processes. For more infor-mation, visit www.sandvik.coromant.com/us, or call 1-800-SANDVIK.

STD Purchases New Facility, Furnace, Machines, and Receives Nadcap Accreditation for Heat TreatmentSTD is a proven leader in the manufac-turing of high-precision (AGMA Q14), complexly configured, tight-tolerance gears, splines, and other related

mechanical transmission components.Registered AS9100 and ISO 9001 on

OASIS as well as Nadcap-accredited in heat treatment and passivation, STD can provide the following services:- Sawcutting - CNC Turning and Milling - Swiss Screw Machining - bWire and RAM (Die Sink) EDM- Broaching - bHoning - bCNC Piece Marking - Heat treating - bPassivation - Isotropic Superfinishing - Tool Design and Tool Making- Surface Grinding and Internal/

External Cylindrical Grinding

STD manufactures products quali-fied for such critical applications as NASAs International Space Station, the Hubble Telescope, commercial and military aircraft, as well as vari-ous defense products. STD has proven consistently to be a reliable quality partner, earning the trust and respect of the finest corporations in the United States.

Tsugami SS32 8 axis CNC Swiss Screw Machine:

The SS32 is a state of the art Swiss Turning Center manufactured by Tsugami Corporation of Japan. The SS32 platform delivers unmatched capability, flexibility and performance. For simultaneous machining, it is sim-ply the best system in its class. Its standard eight cutting axes (X1, Y1, Z1, C1, C2, X2, Z2, and Y2), along with SS Abile Programming Software can make fast work of the toughest applications.

JANUARY 2013 11

Royal Master 12x4 Centerless Grinder Model TG-12x4:This machine has a capacity of 1/16 to 2 in diameter. This machine has through-feed, in-feed, and bump grind capability to include grinding of 6 ft.-long barstock.

SIC c173 L-G Laser Marking Machine:The c173 L-G is a laser station, which produces permanent high-quality mark-ing on the toughest of materials such as carbides, hardened steels, and titanium alloys. It is also suitable for marking plastics and softer metals. The versa-tile c173L-G can mark standard, 1D and 2D Data Matrix codes as well as graph-ics and logos with precise definition and high contrast.

Industrial Building:STD will remain at their current loca-tion on 318 Manley St and plan to use this building as a satellite location to be utilized as their material processing center. At this location they will process all materials to make ready for machining

to include: Sawcutting, Nadcap-accredited heat treating of PH stainless alloys, and precision centerless grinding barstock for their swiss screw machines.

Located 10 minutes from its current location in same town of West Bridgewater, this 5125 sq. ft. industrial building will provide additional space to relieve over-crowding and allow for future expansion.

Delta Heat Treating Furnace to Handle 6 foot PH Stainless Alloys:The Delta H Technologies Model SCAHT is a single-chamber oven system designed specifically for performing a wide variety of aerospace heat-treating applications, including: Stainless steel precipitation hardening, aluminum solution heat-treat-ing, annealing, and aging, as well as

Serving the Gear Industry for Over 20 Years

Gear Grinding Services Featuring

Newer CNC Gear Grinders Calibrated Analytical Gear Inspection

Equipment Up to 200 Piece Lot Sizes ISO 9001:2008

4884 stenstRom RoAd RoCkfoRd, il 61109phone: 815-874-3948 fAx: 815-874-3817

www.raycargear.com

Complete Gear Manufacturing


heat treatments of ferrous alloys requiring less than 1400F. The high-temperature furnace chamber is designed for efficient operation between the temperatures of 250F and 1400 F. A stainless steel roll-away table is featured under the system to allow easy staging of parts coming and out of the furnace.

Drake CNC Thread Grinder Model GS:TE-LM 200:The Drake GS:TE-LM 200 front dress thread grinder is suitable for grinding full length thread on a part with any lead or helix angle, right or left hand. The machine is built on a cast polymer base and is controlled by a state-of-the-art Fanuc CNC. Wheel forms are generated by a servo driv-en, rotary diamond truing device mounted on the worktable. Specifications as well as standard and optional features of the basic machine are set forth below.

- Grinding Length (from Tailstock): 13 inches/330 mm

- Maximum Thread Diameter: 8 inch-es/200 mm

- Lead Angle: +/- 35 degrees- Lead: 0 to 39.33 inches/999 mm- Max Pitch: .4724 inch Module: 12 mm

Slone Gear International Formed in South Central OhioBrian Slone, principal and owner, has announced the formation of Slone Gear

International, Inc. effective March 9, 2012. Slone Gear develops and dis-tributes gear technology products and services. In addition, with over 25 years of experience in the gear metrology field, Slone has assembled a group of top technology companies to source gear components and provide unique solu-tions for producing, measuring, and add-ing life-improving processes for gears and related components for the North American gear market. The company operates on the philosophy that helping gear and spline companies find the right sourcing partner depends on linking the proper level of manufacturing sophistica-tion with the appropriate metrology capa-bility for a perfect technology match at the optimal cost. Slone Gears primary focus is on spline gages/master gears, single-flank, and double-flank function-al gear roll testers, roundness mea-surement machines and work holding/arbors. Slones 15 years of experience developing CNC analytical gear measure-

GEARING AHEAD TO MEET INDUSTRY'S DEMAND FOR PRECISION

--Serving--Aircraft Aerospace Actuation

Instrumentation OpticRobotics Radar Medical

Marine Defense ExperimentalPrototype Production

Hi-Performance Automotive

Precision Gear Products (up to AGMA Q14):Spur Gears, Helical Gears, Worm Gears, Anti-Backlash Gears, Cluster Gears, Clutch Gears, Face Gears, Planetary Gears, Gear Assemblies, Gear Boxes, Bevel Gears, Miter Gears, Metric Gears, Internal Gears, Idler Gears, Gear Rack & Pinion, Worms, Wormshafts, Splines, Spline Shafts, Serrated Shafts.

STD Precision Gear & Instrument, Inc. 318 Manley St. Unit 5 West Bridgewater, MA

02379 (888) STD-GEAR or (508) 580-0035

Fax (888) FAX-4STD or (508) 580-0071 E-mail [email protected]

Web site: www.stdgear.com

Hofler Model 800 CNC Single Tooth Gear Grinder 31 x 60 long with inter-nal grinding capabilities

Klingelnberg P-100 Gear Inspection Machine 40 Dia. Maximum

Custom Gear

New Capabilities

& Machine, Inc.T h e G e a r S p e c i a l i S T S

5466 east rockton rd. roscoe, il 61073 Tel 815.389.6065 Fax 815.389.4548

cgearinc.com

JANUARY 2013 13

ment equipment has perfectly positioned Slone Gear to assist gear companies interested in purchasing new CNC ele-mental gear measurement equipment to evaluate the best metrology solution for their particular gear manufacturing appli-cation/operation.

Other company activities include (1) onsite gear and spline classroom train-ing; (2) continuing investigation of a promising new micro-surface treatment application to extend the life of gears and splines in high-load and heavy-wear environments; and (3) partnership with an international transmission manufac-turer to source gears for a new domestic transmission program.

Slone Gear operates from its offices in Troy, OH, and Coldwater, MI, and a development laboratory in Dayton, OH. For further information contact:

Brian Slone, Vice President of Operations [email protected](507) 401-4327 or Linda Eggleston, Public Relations at [email protected]

Gear Dynamics and Gear Noise Course, April 29 May 2The Gear Dynamics and Gear Noise Short Course has been offered for over 34 years and is considered extremely valuable for gear designers and noise specialists who encounter gear noise and transmission design problems. Attendees will learn how to design gears to minimize the major excitations of gear noise: Transmission error, dynamic friction forces, and shuttling forces. Fundamentals of gear noise generation and gear noise measurement will be covered along with topics on gear rat-tle, transmission dynamics, and housing acoustics. This course includes exten-sive demonstrations of specialized gear analysis software in addition to the demonstrations of many Ohio State gear test rigs. A unique feature of the course is the interactive workshop session that invites attendees to discuss their specif-ic gear and transmission noise concerns. The round table discussions on Day 4 are intended to foster interactive prob-lem solving discussions on a variety of topics. For more information, visit www.gearlab.org.

Gleason and SMT Form Strategic Partnership for Gear Design and Manufacturing SystemsGleason Corporation (Rochester New York) and Smart Manufacturing Technology (SMT) (Nottingham, UK) have formed a global strategic partnership to provide gear manufacturers world-wide

a complete design to manufacturing system. Gleason and SMT will offer a system that seamlessly integrates SMTs premier System Design and Analysis Software (MASTA) with Gleasons indus-try-leading software for Bevel Gear Design and Manufacturing (CAGE). Gear manufacturers will benefit from a fully integrated workflow when designing pow-

From simple keyways to multiple, special profi les, Leistritz Polymat and Polyjet machines have the features to improve quality, shorten cycle times and minimize set-ups.

Polymat series of CNC keyseating

machine

201 934-8262 www.leistritzcorp.comLeistritz Corp. 165 Chestnut Street, Allendale, NJ 07401


ertrains, gearboxes, transmissions and more. The first products from the coop-eration will be available in the first half of 2013.

John J. Perrotti, President and Chief Executive Officer of Gleason Corporation said, We have great respect for SMTs capabilities and are excited about the inte-gration of MASTA and CAGE, and providing

designers and manufacturers of gears and power transmission drives with exciting new opportunities to enhance their processes and products. This is the first step in our partnership with SMT and we look forward to exploring other areas of mutual cooperation.

David Beedan, Operations Director of Smart Manufacturing Technology, adds, Gleason Corporation has a distinguished

history as the world leader in gear tech-nology and we are delighted to be enter-ing into this partnership to enhance the capabilities of both CAGE and MASTA to provide the user with a fully integrated design-to-manufacturing solution.

Gleason Corporations mission is to be The Total Gear Solutions Provider to its global customer base. Gleason is a world leader in the development, manufacture and sale of gear produc-tion machinery and related equipment. The Companys products are used by customers in automotive, truck, air-craft, agriculture, mining, wind power, construction, power tool and marine industries and by a diverse set of cus-tomers serving various industrial equip-ment markets. Gleason has manufac-turing operations in Rochester, New York; Rockford, Illinois; Dayton, Ohio; Munich and Ludwigsburg, Germany; Studen, Switzerland; Bangalore; India, and Suzhou, China and has sales and service offices throughout North and South America, Europe and in the Asia-Pacific region.

Smart Manufacturing Technology (SMT) is a world leading supplier of tools, procedures and expertise for the design, analysis and development of complete transmission and driveline sys-tems. Users of SMTs MASTA software include a large number of blue-chip companies worldwide, operating in a diverse range of market sectors includ-ing automotive, truck & bus, off-road vehicles, wind power, mining and indus-trial machinery. More information about Gleason Corporation and about SMT is available at www.gleason.com and at www.smartmt.com.

Corporate President of Solar Atmospheres, Roger Jones, Recognized for His Years of Service to MTI Board of TrusteesThe Metal Treating Institute recognized one of its long time volunteers, Roger Jones, Corporate President of Solar Atmospheres at its Fall Meeting October 1-3, 2013 in Nashville, Tennessee.

After six years of serving on the Board of Trustees, Roger became President of

A progressive gear manufacturer understands it needs to go above and beyond traditional expectations. Todays customers demand and deserve the latest technology, a wide range of capabilities and an unrelenting commitment to prompt and effective customer service. When it comes to exceeding expectations, Schafer Gear is truly light years ahead. Our investment in the latest production equipment assures that we can provide gears for many industrial applications including transportation, medical, mining, gas and energy, agricultural equipment and many specialty applications. And every gear we make comes with one thing standard the willingness to go to the ends of the earth to serve our customers well.

Find out more at www.schafergear.com or call us at 574-234-4116.

PROCESSES FOR CYLINDRICAL GEARS AS LARGE AS 10,000 mm IN DIAmETER

For worldwide sales locations and additional information, visit:

www.gleason.com [email protected]

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MTI in 2005. In 2009, he returned to the Board of Trustees and has volunteered on numerous committees over the years. Roger was a member of the transition team to the new management company in 2008 upon then CEO Lance Millers retirement and helped rewrite MTIs gov-erning documents. He served on the national meeting program committee and

as a board member of the MTI Educational Foundation.

During the awards ceremony, MTI 2012 President, Buster Crossley from Texas Heat Treating stated, Roger Jones is an icon within the heat treating community and the MTI. He is a selfless individual who always has the industrys best interest at heart. He is the epitome of what a volunteer should

look like for any organization. Mr. Jones reflected, I am honored to receive this award and to have worked with so many dedicated people on the board. The com-mitment to MTI is a family affair. Rogers son, Jamie Jones of Solar Atmospheres, is taking his fathers place on the board starting January 1st. Jamie will begin his first 3-year term representing the Atlantic Coast Chapter. I am proud of my fathers accomplishments through MTI and I am excited to have the experience of serving on the board. I look forward to continuing to grow this great organization. Established in 1933, The Metal Treating Institute is the largest network of heat treaters in the world with plants in 40 states and 8 coun-tries and sales of over $1.4 billion. Solar Atmospheres has been a MTI member since 1983.

The Metal Treating Institute recognized one of its long time volunteers, Roger Jones, Corporate President of Solar Atmospheres at its Fall Meeting October 1-3, 2013 in Nashville, Tennessee. After six years of serving on the Board of Trustees, Roger became President of MTI in 2005. In 2009, he returned to the Board of Trustees and has volunteered on numerous committees over the years. Roger was a member of the transition team to the new management company in 2008 upon then CEO Lance Millers retirement and helped rewrite MTIs governing documents. He served on the national meeting program committee and as a board member of the MTI Educational Foundation.

During the awards ceremony, MTI 2012 President, Buster Crossley from Texas Heat Treating stated, Roger Jones is an icon within the heat treating community and the MTI. He is a selfless individual who always has the industrys best interest at heart. He is the epitome of what a volunteer should look like for any organization. Mr. Jones reflected, I am honored to receive this award and to have worked with so many dedicated people on the board.

The commitment to MTI is a family affair. Rogers son, Jamie Jones of Solar Atmospheres, is taking his fathers place on the board starting January 1st. Jamie will begin his first 3-year term representing the Atlantic Coast Chapter. I am proud of my fathers accomplishments through MTI

JANUARY 2013 17

and I am excited to have the experience of serving on the board. I look forward to continuing to grow this great organization.

Established in 1933, The Metal Treating Institute is the largest network of heat treat-ers in the world with plants in 40 states and 8 countries and sales of over $1.4 billion. Solar Atmospheres has been a MTI member since 1983. Please visit www.solaratm.com for more information.

Cleaning Technologies Group, LLC Hires Dave Melton as Marketing ManagerDave Melton has joined Cleaning Technologies Group, LLC as the market-ing manager, effective November 2012. Dave will provide marketing support for Cleaning Technologies Group by develop-ing and executing marketing activities to build global awareness for the Ransohoff, Blackstone-NEY Ultrasonics, and CTG Asia product lines.

We are confident that with his extensive global machine tool marketing experience, Dave will be an asset to our organization and will play a key role in our push to gain global market share, remarks Chris Whittaker, VP of Sales & Marketing CTG, LLC.

Dave brings over 25 years of marketing experience in the machine tool industry serving as marketing manager for com-panies including Gleason Corporation in Rochester, NY and Makino Inc. in Mason, OH. Dave holds an Associates Degree in Business from Cincinnati State and cur-rently resides in Cincinnati, Ohio with his family. For more information about Cleaning Technologies Group, please visit: www.ctgclean.com.

Taiwanese Company to Receive Seventh Furnace from IpsenA 2-bar MetalMaster was shipped to an Aerospace company in southern Taiwan. This is the seventh furnace that the com-pany has purchased from Ipsen.

This units round hot zone provides a work zone of 72 x 72 (1,830 mm x 1,830 mm) with a normal operating temperature range from 960F to 2,400F (515C to 1,315C). The single-chamber, batch-type vacuum heat treatment system is electri-

cally heated with a gas blower inert gas quenching system for uniform cooling to avoid the deformation or twisting of parts. The vertical chamber is heavy and double-walled to provide full water cooling. The flanged, pneumatically automatic operated bottom cover is designed to ensure safe and convenient positive pressure quenching to 2 bar (or above) absolute pressure.

The MetalMasters enhanced partial pres-sure system helps to negate the vaporiza-tion of alloys at high process temperatures. This unit also incorporated the optional VFD vacuum booster to increase pumping speed and was configured with five indepen-dent zones of controls for exceptional and advanced temperature uniformity control for the high-grade aerospace materials the


company is running. Aftermarket Support and Engineered Components put the cus-tomers needs first, optimizing furnaces to individual specifications and providing parts and services, so the best can continue to be the best.

If you are interested in becoming a part of the Ipsen community, you can join online by visiting www.ipsenusa.com/join-the-commu-nity to be kept apprised of upcoming events, Ipsen news, and special offers.

Mazak Congratulates Brad Keselowski and Penske Racing on Championship WinMazak Corporation, a Penske Racing technical sponsor, offered congratula-tions to owner Roger Penske, driver Brad Keselowski and the No. 2 Miller Lite Dodge Team on a winning season and on earning Penske Racing its first-ever Cup series title. Keselowski secured a 15th place finish at the Ford EcoBoost 400 season finale race at Homestead-Miami Speedway, all that was needed to clinch the 2012 NASCAR Sprint Cup Series (NSCS) Championship for himself and his team. After a sixth-place fin-ish at the AdvoCare 500 race in Phoenix on November 11, Keselowski had 2,371 points and a 20-point advantage over the leader in the NSCS points standings. With the cham-pionship, Keselowski beat five-time cham-pion Jimmie Johnson to bring Roger Penske his first NSCS Championship since his first stock car race 40 years ago.

Keselowskis NSCS Championship comes in his third full-time season, and he is the third driver to win his first NSCS Championship within their first three full-time seasons. He finishes the 2012 season with five wins, 13 top-five finishes, and 23 top-ten finishes. I want to thank Mazak for providing us the machines that make the parts we need to build winning race cars, remarked Keselowski. Its sponsors like them that make this (Penske Racing) a championship organization.

Penske Racing and Mazak have been strong partners since 1994. In fact, Mazak is one of the original group of Penske Racing South sponsors dating back to when Roger Penske founded his NASCAR racing organization. As the Penske organization has grown over the years, so have Mazak applications and involvement with the team.

All of us at Mazak are proud to be asso-ciated with Penske Racing and offer our hearty cheers and congratulations to Brad and the team on a truly well-deserved cham-pionship title, said Brian Papke, president of Mazak Corporation. Papke also noted that racing and manufacturing are both industries where man and machine accom-plish truly amazing things, and success or failure is determined by fractions of a sec-ond. Penske Racing and Mazak possess a deep dedication to achieving perfection driven by a never-ending passion and hun-ger to win in their respective industries, he concluded.

From basic suspension brackets to com-plex custom engine parts, the multi-task-ing capability and advanced technology provided by Mazak production equipment has played a vital role in the success of Penskes IZOD IndyCar and NASCAR teams. While each Mazak machine tool Penske Racing uses in its in-house manufacturing operations serves a unique purpose, all of these Mazaks offer consistency in preci-sion, speed, and performance throughout the part-production process, as well as the versatility to quickly adapt vehicle com-ponents to the ever-changing racing track conditions and racing industry segments. In fact, Penske Racing maintains the team couldnt do what it does on the racetrack without Mazak machine tool technology. To show its support of Mazak, Penske Racing features the Mazak logo on the nose of its IndyCars, as well as on the B-pillars of NASCAR Series cars. For more informa-tion on Mazaks products and solutions, visit www.mazakusa.com or follow them on Twitter at @MazakCorp and on Facebook at www.facebook.com/MazakCorp.

CSIA Adds Standards for Service and Support to Best Practices and Benchmarks ManualTechnical and maintenance staffs are shrink-ing at manufacturing operations in North America and around the world. To help run their operations efficiently, more industry cli-ents are turning to members of the Control System Integrators Association (CSIA).

More CSIA integrator companies are re-quired by their customers to commit to ser-vice and support contracts. These business-es no longer have enough qualified people

on staff to do the job, says Jeff Miller, chair of CSIAs Best Practices Committee. CSIA believes the need is critical enough to cre-ate an integrator best practice around it.

CSIA added a section on service and sup-port to the Best Practices and Benchmarks Manual when it was revised in 2012. CSIA updates the manual every few years to keep pace with the changing environment of control system integration. The manual provides integrators with industry-proven best practices in areas of general manage-ment, human resources, marketing, finan-cial management, project management, system development lifecycle, supporting activities, and quality assurance.

Miller says large manufacturers and pro-cess plants are driving this service-and-support trend. Many engineers are reaching retirement age and are not being replacedoften because engineers with specialized technical expertise cant be found in a tight labor marketso companies are looking for CSIA integrators because fewer staff members have the skills to respond to high-tech issues.

A plant engineer is often called on to troubleshoot mechanical and electrical issues in the plant, but they seldom write code for the overall plant control system and struggle at times to dig into it to determine the problem, maintains Miller. Every day, CSIA members provide the marketplace with control system expertise. We stay on top of new technology and know how to use it.

CSIAs Best Practices and Benchmarks Manual offers a defined process for deliv-ering service and support that is differ-ent from integrator-supported projects. It guides CSIA members on how to best work with clients in this role. For more informa-tion on CSIAs Best Practices or how to Find an Integrator, visit the CSIA website, www.controlsys.org.

Founded in 1994, the Control System Integrators Association (CSIA) is a not-for-profit, global professional association for control system integration companies. Control system integrators use their engi-neering, technical and business skills to help manufacturers and others automate their industrial equipment and systems. CSIA members provide a range of services in dozens of industries.

JANUARY 2013 19

TCalifornia, Here We ComeThere is no other state like Califor-

nia. Within its 850-mile north to south

track, it is our most populous state and

one of the most diverse geographical,

economic, and cultural regions in the

United States. Come with AGMA to

Southern California, where, since the

16th century, it has been the ultimate

melting pot. This area was home to

the first Spanish settlement in America.

Now, in lieu of missions, this area is

now renowned for sunny warm weath-

er, The Beach Boys, and, more recently,

a thriving community defined by tour-

ism and the defense and aerospace in-

dustries.

This is a first for the AGMA and

AGMA members, as we venture into

the warm Southern California sun for

our annual opportunity to network and

bring home the latest best practices

from fellow gear and bearing industry

executives.

Whether you are new to the associa-

tion or an old pro, I hope you con-

sider joining over 250 of the current

and future industry leaders from the

American Gear Manufacturers As-

sociation and the American Bearing

Manufacturers Association when they

convene at their joint annual meeting,

April 25-27, at the Park Hyatt Aviara

Golf Resort in Carlsbad, CA.

More than 150 years ago, thousands

of people migrated to California, where

they joined forces and tested their luck

in the gold fields. Fast forward to 2013.

Whether you are a veteran or a first

timer annual meeting attendee, ex-

pand your horizons and join your col-

leagues in the Golden State. Here, you

will increase your knowledge of the in-

dustrys presentations and experience

the majesty of Southern California in

and around Carlsbad, Oceanside, La

Jolla, and Miramar. In this year, you

will bring home ideas, meet new busi-

ness associates, and create a lifetime of

memories.

The planning committee has created

a meeting experience that is sure to

prepare you and your businesses for the

coming years. In addition to the edu-

cational sessions, it will be a great time

to engage in dialogue with your peers

and keep the industry progressing on

the post-recession road.

The speaker line-up for the meeting

is top-notch. They will present topics

that will inspire you and provide you,

your company, and your colleagues

with much needed updates and knowl-

edge on several important business re-

lated topics.

The meeting kicks off with a pre-

sentation by Jim Abbott, former MLB

player and motivational speaker, who

will share his life principles of ADAPT-

ing. You will learn how his personal

challenge of adapting to pitching in

the major league minus one arm forced

him to learn how to break down chal-

lenges into five key strategies, which he

has translated into a successful business

model.

Madelaine Morgan, CMPDirector of MeetingsAmerican Gear Manufacturers Association



CAlenDAr of eventsWhether youre looking for technical education, networking opportunities, or a way for your voice to be heard in the standards process, the AGMA has something to offer you. If you would like more information on any of the following events visit www.agma.org or send email to [email protected].

**Event open to AGMA members only. Not a member? Send e-mail to [email protected].

Lubrication Committee Meeting January 8, 2013 WebExCutting Tools Committee Meeting January 9, 2013 WebExSound and Vibration Committee Meeting January 9, 2013 WebExEnclosed Drives for Industrial Applications Committee Meeting January 10, 2013 WebEx Nomenclature Committee Meeting January 11, 2013 WebExWormgearing Committee Meeting January 15, 2013 WebExVehicle Gearing January 16, 2013 WebExHelical Gear Rating Committee Meeting, January 17, 2013 WebExBevel Gearing Committee Meeting January 22-23, 2013 Orlando, FLEpicyclic Enclosed Drives Committee Meeting January 24, 2013 WebExAerospace Gearing Committee Meeting January 28-29, 2013 Seattle, WATDEC Meeting January 29, 2013 Orlando, FLMill Gearing Committee Meeting Subcommittee 6014 January 30-February 1, 2013 WebExGear Accuracy Committee Meeting January 30-31, 2013 Orlando, FL

Plastics Gearing Committee Meeting February 5-6, 2013 Atlanta, GAGear Materials: Selection, Metallurgy, Heat Treatment, and Quality Control February 6-8, 2013 Clearwater Beach, FLWind Turbine Committee Meeting February 6-7, 2013 Denver, COPowder Metallurgy Committee Meeting February 7-8, 2013 Atlanta, GASpline Committee Meeting February 7, 2013 WebExComputer Programming Committee Meeting February 7, 2013 WebEx

Helical Gear Rating Committee Meeting March 5-6, 2013 Chicago, ILMill Gearing Committee Meeting (6014) March 7, 2013 WebExGearbox CSI - Forensic Analysis of Gear & Bearing Failures March 12-14, 2013 Baltimore, MDVehicle Gearing Committee Meeting March 20-21, 2013 Detroit, MI

Basic Training for Gear Manufacturing April 8-12, 2013 Chicago, ILFine Pitch Gearing Committee Meeting April 9-10, 2013 Hartford, CTFlexible Couplings Committee Meeting April 16-17, 2013 San Antonio, TX2013 AGMA/ABMA Annual Meeting April 25-27, 2013 Park Hyatt Aviara Carlsbad, CA

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JANUARY 2013 21

AGMA opens its 2013 education schedule with Gear Materials: Selec-tion, Metallurgy, Heat Treatment, and Quality Control, February 6-8. The course, taught by popular instructors Raymond Drago and Roy Cunningham of Drive Systems Technology, Inc. will give gearing pro-fessionals the tools needed to select the best materials for a project, and to optimize the finished project through consideration of the metal-lurgy and heat treat process.

Ideally, the design of an optimum gear set requires the coordinated ef-fort of the gear design engineer, the gear metallurgist, and the bearing system engineer. The gear is, after all, part of a larger gearbox system thus it cannot be designed in a vacuum. After the basic requirements of the system are met the system must be sized to carry the expected loads. As part of this process, the materials and heat treatment opera-tions to be used for the gears must be selected. In the best case, this is a collaborative effort between the gear design engineer and the gear metallurgist. The presenters have designed gear systems as a collab-orative effort, together, for more than 40 years. This seminar is their effort to convey both their experience in the process of working as a team and the expertise they have developed for the complete design of geared systems over these many years.

As one student commented, I found it very informative and a nice balance between gear design, which I was unfamiliar with, and heat treatment, which is a little more up my alley.

Some of the topics to be discussed are: initial gear material selection; heat treatment processes and their relation to gear performance, cost, reliability, and load characteristics; engineering drawing development; review of the engineering drawing; understanding melt processing; and gear materials.

Additionally, the seminar will compare the various carburizing pro-cesses and how to optimize the cycle; discuss why the metallurgist should review the manufacturing process sequence, the heat treat facility and laboratory. The instructors will also provide examples on how to complete a metallurgical heat treat test sample and how to evaluate the results.

A wide variety of gearing professionals can benefit from this course including:

Gear design engineers Management involved with the design and manufacture of gearing type components

Metallurgists and materials engineers Laboratory technicians Quality assurance engineers Furnace design engineers Equipment suppliers

The entire course outline and registration information are available at www.agma.org. Participants will receive a certificate of completion at the conclusion of the course, and this course is part of the Advanced Gear Engineering Academy.

AGMA BeGIns 2013 WItH MetAllUrGY CoUrse

Additional topics will include updates on the current fiscal and

economic climate in Washington, the current political environment

for manufacturing, and how this will affect potential key legislation.

Among the speakers who will address these important topics include:

Jay Timmons, President and CEO of the National Association of

Manufacturers (NAM) and Jim Meil, Vice President and Chief Econ-

omist, Eaton Corporation.

Along with the presentations, the attendees are invited to continue

networking during the annual golf tournament which will take place

on the Park Hyatt Aviaras Arnold Palmer-designed course. This

course meanders along the Batiquitos Lagoon, home to shorebirds

and a variety of natural vegetation. Aviara was carefully designed

over nearly a decade to help protect the ecological habitat of these

species.

Friday night, April 26, attendees will have the experience of a life-

time with an inclusive tour of the USMC Air Station, Miramar. The

trip will include a visit to the actual flight line at Miramar, former

home to the militarys elite Top Gun school, and several opportuni-

ties to have one on one interaction with active duty pilots. Imagine

the thrill of looking into the cockpit of an F/A-18 Hornet or under

the blades of a CH-53 Super Stallion! Pending base operations, the

group may witness an actual aircraft take-off or landing. USMC Mi-

ramar is the only functioning Marine Air Station in the world that

permits group visits in this manner.

The meeting concludes on Saturday night, April 27th with clas-

sic entertainment from the 1960s. The Los Angeles-based group Oh

What a Night Boys from Jersey will step back in time and relive the

great songs by Frankie Valli and the Four Seasons.

The Park Hyatt Aviara promises to be a comfortable and conve-

nient setting for peer-to-peer interaction. The resort is located on

200 acres of lush hillsides and rolling valleys overlooking the Pacific

Coast, 45 minutes north of the San Diego International Airport.

Further information about the joint meeting, including registra-

tion, hotel reservations, agenda, and program updates are located

on the subsequent pages or online at www.agma.org. Any additional

questions can be directed to AGMA at 703-684-0211.

We look forward to seeing you in Southern California and show-

ing you how this experience can impact you personally as an indus-

try leader and your company as you plan for the future. This is a

cant miss event in a perfect setting, accompanied by interesting

colleagues, exciting adventures, and golf, all wrapped up into a mem-

orable three-day opportunity.

February 6-8, 2013 Sheraton Sand Key Hotel, Clearwater Beach, FL

CAlIfornIA Here We CoMe continued


Norbert Benik: VP of Industrial Sales, Ontario Drive & Gear, Ltd.

Dean Burrows: President, Nixon Gear, Inc.

Sulaiman Jamal: Managing Director of Bevel Gears India Private Limited

Steve Janke: President, Brelie Gear Co., Inc.

Jan Klingelnberg: CEO, Klingelnberg Group

Tom Marino: President & CEO, Gear Technology

Mark Michaud: President, REM Surface Engineering

Gordon W. New: Managing Director, Ronson Gears Pty, Ltd.

Bob Sakuta: President, Delta Gear

Michael T. Smith: VP of Sales and Marketing, Capstan Atlantic

Michael E. Suter: VP of Marketing, Emerson Industrial Automation

Dirk Wernecke: Global Manager Pricing, Timken Company

AGMA leADersHIP

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Matt Mondek: Chairman

Louis W. Ertel, President & CEO, Overton Chicago Gear Corp.: Treasurer

John Strickland, VP of Marketing and Strategic Planning, Fairfield Manufacturing Co., Inc.: Chairman, BMEC

Dr. Phil Terry, Metallurgist, P. Terry & Associates: Chairman, TDEC

Dave Ballard, Director of Marketing & Business Development, Siemens Industry, Inc.: Chairman Emeritus

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Joe T. Franklin, Jr.: President

Charles Fisher: Vice President Technical Division

Jill Johnson: Director, Member Services

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1001 N. Fairfax Street | Suite 500 Alexandria, VA 2314

(703) 684-0211 | www.agma.org

General requests: [email protected] | Membership questions: [email protected] | Gear expo information: [email protected] Technical/standards information: [email protected] | AGMA foundation: [email protected]

Gear Expo 2013 is only nine months away. The show will help you stay ahead of the business cycle, and it only happens once every two years. Dont get left behind as the industry moves forward. Mark your calendar now for September 17-19 for the worldwide gear industry event in India-napolis.

Heres what youll get from attending Gear Expo 2013:

- Efficient solutions to streamline your workflow, reduce errors and increase productivity. You can browse the ex-hibits, compare product features side-by-side, and capitalize on show specials from the worlds leading manufacturers. Save time and money at just one show.

- Twice the business with only one trip

away from your office the ASM Heat Treating Society Conference & Expo-sition is co-locating with Gear Expo 2013. That means more access to more exhibitors and emerging technologies impacting the gear industry.

- A chance to see the heavy equipment in person and in action, allowing you to put the machinery through its paces before you make a large acquisition. Youll easily make up the time out of the office by holding a years worth of business meetings in just three short days.

- The latest trends and best practices that will improve your profitability. Gear Expo offers affordable, respected, gear-specific curriculum led by experts in their field. The Gear Expo Solu-

tions Center also provides FREE edu-cation on the show floor that can help you solve your manufacturing predica-ments. The ROI on that knowledge will more than pay for your trip!

This is an opportunity to visit a global gear-specific event thats located in a convenient and affordable city. Indianapolis is centrally located to more than half of the U.S. popula-tion, within driving distance for many or you can take one of numerous daily flights.

More than 170 exhibitors have already committed to exhibiting at Gear Expo 2013. The Show floor is almost sold out, but if you want to meet qualified attendees actively seeking to purchase your products and equipment there are still a few spaces available.


tHe CoUntDoWn to GeAr exPo HAs BeGUn!

Need High-Quality GearsFor Off-Highway Applications?

Childs Play...At Forest City GearConstruction, mining and agricultural vehicles and equipment are pushing into some pretty out-of-the-way places these days. Vital components like gears are expected to operate smoothly, quietly and around the clock in the harshest environments and reliability is paramount. Forest City Gear is pushing into new frontiers as well like helping design, develop and manufacture larger gears for some of the leaders in these industries.

Lets have some fun together. Visit:www.forestcitygear.com.

11715 Main Street, Roscoe, IL 61073815-623-2168


chance of being successful. For instance, other heat treatment exercises using thin rings reflect a radial shrinkage but no warping, ovality, or cylindricity changes where recorded. WZL (Grser et al.) have done extensive trials showing slightly higher distortions of PM gears due to radial shrinkage. However, these types of distortions can be accounted for in tooling and corrected in hard finishing.

The shape of the material slug used for gear cutting tends to have an influence on the final shape of the gear. A gear from powder, however, does not have this memory effect due to its isotropic material microstructure.

Another feature with PM gears is that the root can be optimized and reduce stresses. An interesting phenomena is that the stresses from dynamic impact loading is reduced ever further than the static stress from bending. Therefore, this design technique improves robustness when the transmission is misused. This technique is also employed in the manual 6-speed build discussed earlier. The problem arises when making prototypes it proves impossible to cut with a profile cutter or grinder, and we are presently struggling with this. Wire cutting is not an option for PM since it tends to decarburize the material and create micro-cracks. Anyone with an idea is welcome to send me an email!

Besides improving the gears using the manufacturing freedom that PM offers, it is also possible to cut manufacturing steps by, for instance, having the article number engraved in the punches thus saving a markup step in the manufacturing process. Chamfers on the gears, to avoid over carburizing or corner chipping, may be put in the tooling and made directly in the compaction step, also saving a step in the process chain. Other possibilities to be manufactured directly in compaction, could be a groove, shoulder, or notch that may be introduced, making it impossible to assemble the PM gear in the wrong way, a practice that is employed in many PM parts today and taught in the Design for Assembly literature.

Our next article will discuss how different property-boosting technologies put an extra step into the manufacturing process. They go under different trade names, but common for them all is their removal or reduction of porosity. The issues discussed in this article are dealt with in more depth in papers downloadable from our website www.hoganas.com/en/News-Center/Published-Articles/.

In the prevIous artIcle, the mIcro desIgn, in the sense of profile modifications to the teeth, was discussed. This fourth article will deal with the possibilities using macro design of the gear body.

In powder metal (PM) component manufacturing, the compaction press normally has several hydraulic cylinders controlling the different tool parts. This allows for individual control of the different sections of the gear wheel, such as teeth, hub, and web. It becomes possible to change the height or density for different parts of the gear body. The designer can then optimize the web thickness to allow for material reduction without turning metal into scrap. Under certain circumstances, it is also possible to put holes in the web section, enabling better flow for the cooling media used in the case carburization process, or for saving weight and material cost in the gear system since no material is wasted in the process. As long as stiffness is maintained in the web so that elastic deformation stays within what the lead and involute crowning can compensate for, the lower level of web thickness is 3-4 millimeters.

A recent design of a powder metal 6-speed manual transmission, presented in Yokohama by the author, showed a weight reduction of 1.1 kg on the gears while maintaining structural integrity and reduction of transmission error and stress levels. This transmission is now being prototyped to be put in vehicle tests.

Similar results were obtained when redesigning an AMT for a small sub A-class car. That prototype transmission now has 110,000 km on its odometer. Rig tests show that it is good for 200,000 km, which is what the transmission is designed for.

Another type of web designed is being investigated and prototyped (see figures 1 and 2). This corrugated web is designed for increased stiffness while keeping material and weight to a minimum. For now it is machined; but a compaction tool is currently in development, and the gears from the tool will go in to the 6-speed manual car transmission mentioned above.

Observing forged gears with a corrugated web reveals: Heat-treatment distortions with this particular design tend to affect the gear teeth, making the gear teeth and gear-rim slightly corrugated as well. At the time of this article, no heat treatment tests have been made with the PM corrugated web design. It is predicted, due to the isotropic non-directional behavior of the PM material, that this has a good

ABOuT ThE AuThOR: Anders Flodin earned his PhD on gear wear and failure modelling at the Royal Institute of Technology, Stockholm, Sweden, and continues to work in powder metal gear technology as a Hgans AB employee in Sweden. Contact him at

[email protected], or call +46 42 338906.

MATERIALSMATTER

Better flow for cooling media, weight and error reduction, and root optimization are all beneficial results for using powder metal gears.

andersFLoDin Powder metal gear processes, Hgans AB

JANUARY 2013 25

or deflections will create a problem for the gear. The tooth thickness is especially critical to the control of the backlash. The functional thickness is observed by checking with the mating gear and measured by a vernier caliper. When meshed together at the proper mounting distance, the backlash can be checked. The tooth thickness is specified at the mean normal tooth section.

BasIcs of the gear desIgn A gear set design commences with the basics such as outside diameter, number of teeth, etc. The bevel gear design requires the ratio and the calculations for the size and capacity using the load carrying formulae from the recognized AGMA or ISO standards. The suggested factors are reliable, having been established with many test programs. An additional task is to design the Ease-Off. It is computed mathematically by determining the minimum meshing distance for a set number of teeth. This provides a graphical presentation of the pinion and ring gear crowning which affects the contact pattern and running condition. Straight bevel gears usually have a minimum of 12 teeth. The fewer number of teeth used by spiral and hypoid bevel gearing is possible through the additional overlap formed by the oblique teeth, permitting the teeth to be stubbed, which prevents undercutting and still provides an acceptable contact ratio. Straight bevels avoid stub teeth because of the reduction in contact ratio which would affect sound level and wear.

In theory, the tapered teeth become weaker as they are elongated, and full-length contact is unlikely as the teeth are lengthened. A general rule for the maximum face width is to divide the cone distance E by three.

Teeth with either long or short addenda are used on gears other than miter gears to avoid undercutting, increase the tooth strength, and reduce the rate of wear. By adding the addendum angle to the pitch-cone angle, the face angle between the axis of the gear and tops of the teeth are obtained. The tangent of the addendum angle equals the dedendum divided by the cone distance E.

TOOTHTIPS

Accurate thickness, taper, gear blanks,

proportions, and other specifications are

necessary for maximum gear performance.

williamCrosherAuthor, engineer, and former director of the

National Conference on Power Transmission

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

book Design and Application of the Worm Gear.

ABOuT ThE AuThOR:

gear Blanks

Bevel gears are almost always produced from shaped blanks. Therefore, more care and attention has to be taken in the selection of the gear blank than with other gear forms. As with all gears, sufficient thickness of material is required under the gear tooth roots. The taper of the bevel gear has to be taken into consideration, and it is recommended that the minimum amount of material should be at least equal to the whole depth of the tooth. Gears that are going to be highly stressed need a thicker section. The thickness must also be maintained under the

small end of the teeth. The blank geometry is set together with the initial settings for the coordinated movement of the blank and cutter. Because of the complex nature of the bevel gear, the blank design is of major importance. It is also necessary to provide a flat clamping space, and the back of the gear should

be machined square with the bore and parallel with the front clamping surface. The aerospace and helicopter industries have produced a large body of data on the application of bevel gearing. Of major significance have been the effects of rim thickness on gear tooth stresses. Some ring gears require a web-less type of blank. Then the thickness between the bottom of the tapped hole and the root line of the gear should be one-third the tooth depth.

The blanks supplied for all bevel gears must be within acceptable limits. These tolerances are applied to the face and back angles, outside diameter, the crown to back, and bore. Proportions are also critical to gear performance; the bores, hubs, and locating surfaces must be in relative size to the gear diameter and pitch problems occur with small bores, thin sections, and any conditions that cause difficulties in holding the blank or provide excessive overhang.

Almost all bevel gears that have a center hole when being machined are held by a clamp plate on the front face. The blank must incorporate a suitable surface for this purpose. Any excessive local stresses and/

addendum angle

dedendumangle


fired grid in Ohio or Michigan would cost about $0.07 per hour. So if your toaster runs for two minutes it will cost you $0.002. The toaster requires probably 850 watts/hour [0.85 kWh].

A 3,000-pound capacity furnace heated to 1750F [954C] requires 144 kW for 90 minutes and will cost $15.12. If youre a renewable energy advocate living in the middle of an Arizona desert with a several thousand-panel solar array, running your toaster for two minutes with solar power will cost $0.42. If you live in the Great Lakes region, forget solar; you need at least five hours of direct sunlight all day, every day of the year. Needless to say, industrial applications for solar power are few and far between. Wind-produced electricity is a more viable option for industry when the wind is blowing (which is not a guarantee, so supplemental traditional power plants will still be required). Although wind turbines are more economical and practical than solar for industrial applications, they still present reliability issues.

Heating the 3,000-pound carburizing furnace with natural gas is not as efficient as electricity, because a portion of the combustion products and the associated heat must be released in order to keep only the hottest portion of combustion products within the furnace.

The carburizing furnace uses gas-fired radiant tubes in which burners, ignited by a special spark plug push a 10-to-1 air-to-gas mixture through the U shaped tube. The burners air/gas velocity is designed to create a flame front long enough to travel down the length of the firing leg and allow only the products of combustion [flue gas] to return back up the exhaust leg and out of the hot zone. This assures that the hottest portion of combustion products remain within the return leg of the tube. By comparison, your home furnace, if built in the last 15 years, is designed to keep 85 to 90% of the heat produced within the combustion chamber. A carburizing furnace with 65% efficiency exhausts 35% of the 1,200,000 BTUs from the radiant tube. Even so, the cost of residential natural gas in Ohio and Michigan is approximately $4.20 per 1000 cu. ft. or 1,000,000 BTU. The industrial rate price is likely $2.50 to $3.50 depending on the monthly consumption. By comparison, when heated by electricity for $15.12, the 3,000-pound carburizing furnace operating for 1.5 hours heated with natural gas at $0.35 per therm [100,000 BTU] will cost $4.20, without any efficiency improvement. This is the reason natural gas is the preferred option: It is less than 1/3 of the traditionally produced electrical cost.

do you have gas? every year we encounter at least one OEM or new heat treater looking at heat treating in-house, and we ask them that question when it comes to heating their furnaces.

Except for some regional exceptions, natural gas is the preferred choice in the U.S., primarily because its less expensive than electricity per unit of energy. In Europe, natural gas is also more economical, but there are locations where the natural gas infrastructure is insufficient, so electric heating is the only real option. China and Russia have the same issues.

To manufacture everything that doesnt grow from Mother Earth requires energy at some time during its evolution. And the tools (and the tools we use to make those tools) that manufacture everything will use gears at some point; gears from gigantic mining machines to chainsaws are heat treated in some form.

Here is the breakdown for the electricity sources of furnaces, per the U.S. Energy Information Administration (August 2012): 37% coal; 32% natural gas; 17% nuclear; 6% hydroelectric; 2% wind. These total 94% the remaining 6% are renewable sources, including solar (0.11%) and wood (0.81%). Various organic sources such as biomass and other obscure renewables make up the rest.

Electricity to drive motors, valves, switches, and the like doesnt generally consume huge quantities of power unless the motors become very large. Demand for electric energy skyrockets when used to generate heat. However, heating by electricity does have one thing going for it: Efficiency. Resistance-heating elements, for example, turn electricity directly into heat, as does the combustion or oxidation of fossil fuels. Electric energy gets very expensive as 1) efficiency decreases and 2) it is transformed via induced power to or from different voltages.

So whats the cost? Consider two items at opposite ends of the energy consumption spectrum: The everyday household toaster and a 3,000-pound batch-carburizing furnace. To operate the toaster with energy generated by a coal-

HOTSEAT

Gas and electricity are both viable energy

sources for heating furnaces, but there are

ecomomic and energetic reasons to pick one

over the other.

jacktitusDirector of process and developmental engineering, AFC-Holcroft

Jack Titus can be reached at (248) 668-4040 or [email protected]. Go online to www.afc-holcroft.com or www.ald-holcroft.com.

ABOuT ThE AuThOR:

No room for error?

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By Tim Byrd

COMPANYPROFILE

A tight-knit family environment and a commitment to excellence has kept this Worcester, MA company ahead of the curve for 50 years.

Kinefac Corporation

JANUARY 2013 29

TThis place is a second home for me, says Charles Gar-niewicz, director of research and development for Kine-fac Corporation, now celebrating their 50th anniver-sary. He proudly describes his 43-year attachment to the Worcester, MA-based company that has been making quality rolling machines for half a century. His is a com-mon sentiment among the companys 50-plus employ-ees, whose goal is continual improvement in anything they do.

The company was founded in 1962 by my father, How-ard Greis, said President Noel Greis in recounting the companys rise to become an internationally known man-ufacturer of forming and turning machines and systems. Our first products were rolling machines. We manufac-tured machinery for the production of threaded parts, largely for the automotive and appliance industries at the time. In the 50 years since then, weve grown consid-erably in our capabilities.

Part of our goal is to be continuously innovative in anything we do, Garniewicz goes on to say. We want to make it better, faster, less expensive, more accurate. Specifically, in terms of gearing, we have machinery in the field that is improving the surface finish of ground worms. These worm shaft blanks are ground with an 8, 9, or 10 Ra finish, and we are improving the finish down to 3 to 5 Ra in an automated roll forming operation. We try to stay ahead of the curve, and to work with new and developing technologies. For example, we were chal-lenged to design and build a rolling machine that was submerged in 450F oil for ausforming gears. It was a novel approach, where we start with a pre-formed pow-der metal gear and pass it through induction heating coils to raise the surface temperature required for aus-forming. We then plunge the heated blank into a tank containing 450F hot oil as well as the roll forming tool-ing. The blank is then roll-sized and finished to produce the densified and ausformed gear. For us, that was quite a challenge.

The patented Kine-Roller started out as a machine to roll form threads. Conceptually, each of the forming dies moves toward the central work axis, which was dif-ferent from the machinery that was available in the early 60s. Because of that feature, it required far less com-plicated work support tooling. In the late 60s, we were involved with the manufacture of machinery to roll B-7 studs and high-speed thread rolling. Later in the 70s, we worked on a through-feed and cutoff process, where we converted up to 20 long pieces of rod or tube into elements such as balls, rollers, and other cylindrical shapes at high speed. Some of the machines we de-veloped and sold with this process in the 70s are still currently in production. In the late 60s, we developed our own CNC 4-axis grinding machine for the production of variable lead dies used in producing these cut off shapes. Back then, that was considered a unique piece of equipment.

Today, the company is recognized as a world leader in precision metal forming and processing technology. They produce metal forming machinery for the produc-

tion of high-precision threaded fasteners for the aero-space industry, large and hard-threaded rods for the nuclear energy industry, turning equipment for construc-tion and automotive industries, and coil manufacturing equipment for the medical device industry. In addition, Kinefac also provides hydraulic power units and compo-nents, centrifugal cleaning equipment, and automated gate systemsall engineered and built at their home in Worcester. At the turn of the century, the city of Worces-ter was the mechanical engineering center of Massachu-setts. Right now, Kinefac appears to be the last privately held machine tool manufacturer in the city as a result of the extra effort that they have put in to satisfy all their customers.

In 2004 Kinefac expanded their innovative rolling ma-chines to China, making the machines here in the US and shipping them overseas for their customers. Charlie


admits it was a learning process, and that they didnt know the full ramifications of going over there!

What we learned in China is that it takes a while to get rec-ognized, explains Richard Risotti, vice president, global sales. The key is to develop new technology, listen closely to the people that you talk to, see what their ideas and needs are, and develop a process from there. What weve learned during the past eight years in China is that the depth and complexity of what is required continues to evolve after the purchase order, so that in the quot-ing stage, you have to be very careful and specific about what you plan to do. International customers are far more concentrated on specifics than the American market is. Youve got to be care-

ful, dotting your is and crossing your ts. You have to build trust and develop a relationship. The Chinese call this relationship, a continual building of trust, Guanxi. Primarily targeting the aero-space, power generation, and railway markets, Kinefac has been very successful there, with almost 80 machines to date.

Now they are taking this acquired experience to their next pros-pect: India. With a sales service center in India, Kinefac is seeing potential growth for the same type of markets as those in Chinaaerospace, automotive, and powerand they are committed to fully encompass the markets that they serve.

Back in Massachusetts, Kinefac lives out its continuing-edu-cation philosophy through the local college, Worcester Polytech-nic Institute. Kinefac engineers have presented plant tours and engineering discussions to various manufacturing classes at WPI. Some students complete their MQPs (undergraduate proj-ect requirement) at Kinefac headquarters, a 57,000 square-foot facility. Its clear this company is just as firmly committed to the engineering community down the street as it is to the global market overseas. Their technology team consists of about 14 people who meet on a weekly basis. They get together and dis-cuss current and future projects. Kinefacs long-term employee base is an example of how to complement each other in order to get the job done.

TO LEARN MORE: Call (508) 754-6891, email to [email protected], or visit online at www.kinefac.com.

Saving Time and Cost for Intricate Gear PeeningPrecision shot peening eliminates the need for masking and reduces distortion. An efficient upgrade from traditional shot peening, it also reduces labor and process time.

By Ruthann Browning

SSHOT PEENING IS A COLD WORKING PROCESS USED TO PRODUCE A COMPRESSIVE RESIDUAL STRESS LAYER AND MODIFY MECHANICAL PROPERTIES OF METAL BY IMPACTING A SURFACE USING ROUND, BEAD-LIKE PARTICLES WITH SUFFICIENT FORCE TO CREATE THE REQUIRED COM-PRESSION DEFORMATION. THESE PARTICLES CAN BE MADE OF VARIOUS METALS, GLASS, OR CERAMICS. USING MASS AND VELOCITY, EACH PARTICLE FUNCTIONS AS A TINY BALL-PEEN HAM-MER AS IT IMPACTS THE PART AND LEAVES A SMALL INDENTATION ON THE SURFACE, CREATING A COMPRESSIVE RESIDUAL STRESS LAYER IN THE SURFACE OF THE PART.

SHOT PEENING SIGNIFICANTLY IMPROVES PART PERFORMANCE AND LIFE. BENEFITS OF SHOT PEENING INCLUDE IMPROVEMENTS IN: FATIGUE LIFE (TORSIONAL, AXIAL, BENDING, AND THER-MALLY-INDUCED FATIGUE), FRETTING, PITTING, GALLING, AND CORROSION FAILURES (STRESS CORROSION CRACKING, EXFOLIATION, AND INTERGRANULAR CORROSION). IT HAS BEEN DEM-ONSTRATED THAT MOST CRACKS WILL NOT FORM OR GROW IN A HIGH-COMPRESSION STRESS ZONE. SINCE NEARLY ALL FATIGUE AND STRESS CORROSION FAILURES ORIGINATE AT OR NEAR THE SURFACE OF A PART DUE TO TENSILE STRESS, THE COMPRESSIVE STRESSES INDUCED BY SHOT PEENING INCREASE PART LIFE. DEPENDING ON THE SHOT MATERIAL, QUALITY, INTENSITY, COVERAGE, AND PART GEOMETRY AND MATERIAL, SHOT PEENING CAN INCREASE FATIGUE LIFE UP TO 1,000%.

some ChALLenges in shot PeeningWhen using traditional shot peening systems, which provide blanket-type shot blasts of media to any surface being peened, manufacturers must either make elaborately-fixed jigs to cover gear tooth faces to remain un-peened, or hand-tape/mask each of these areas to prevent them from being peened. The big nozzle of the machine then blasts away until the gear is completely processed. The gear is then removed, unmasked, and goes on to its next process step. This operation requires a substantial air compressor and, because the media is propelled in a wide blast, fragments continually hit the interior walls of the peening chamber. This requires the chambers to be reinforced with internal steel panels simply to ensure the life of the system itself.

Some traditional automated shot peening systems have indexing tables that allow operators to place parts on them and index gear assemblies into the machine for peening. However, each gear assembly is still shot-peened individually. The alternative is to place them in a wheel-type system and peen several at once. Both processing arrangements still require the gear or part to be masked in order to protect the areas that are to remain un-peened. Developing and maintaining special tooling, and the labor-intensive process of masking, both add substantial cost and process time to the project.

introDuCing A new wAy to shot PeenPrecision shot peening brings an entirely new concept to this field, and is complementary to its larger cousin. Using glass bead media, Comco has been shot peening for years

with microabrasive blasting technology. A major difference with the microblasting approach is it that uses very fine media (150 micron or finer). Also, the media can only be used once. Shot peening media is larger and is reclaimed for reuse. However, the theory behind both microblasting and shot peening is basically the same: Accurately mixing air and media and then shooting it at a target part. Taking the step from microblasting to precision shot peening was a matter of designing a new and larger automated system to handle and recycle larger media. This has to be done within a larger, automated processing chamber that contains the process and still works with the highly-focused precision of an automated lathe microblaster.

A precision shot peening system can blast the valley in any size gear, without masking, while consuming far less energy than a large nozzle or wheel-type, traditional shot peening system. It brings an entirely new concept to this field.

Precision shot peening takes a highly focused approach to peening. Typical nozzle sizes are 0.060 to 0.185 ID. This smaller nozzle size creates a very collimated, well-controlled media stream, and ensures 100% of the media hits the part. The nozzles move above the part and focus the peening blast directly at the area to be strengthened.

Coupled with automation, a precision shot peening system needs no protective steel plating as required in the much larger, traditional shot peening systems. Gears and gear assemblies to be peened require very little or no masking at all. The system is also much less costly to operate because it requires a smaller air compressor unit and utilizes the media much more efficiently. The media is not broken down or wasted by hitting the sides of the machine instead of the part. It is recovered, resized, and recycled for future use.

JANUARY 2013 33

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The smaller nozzle size and tighter automated control allow a precision shot peening system to process multiple parts at the same time, depending on size. Also, standard shot peening machines can peen with either ferrous or non-ferrous material (they usually cant handle both). Precision shot machines can deliver all media types. They can even deliver multiple sizes of the same media type simultaneously.

how it works Precision shot peening equipment requires metering exact quantities of media and air, ensuring the tightest process control. It does this by positively introducing media into the air stream, as opposed to methods used by traditional shot peening equipment (gravity, syphon, or magnetic feed systems that have control limits). The system sorts and stores three different sizes of media to allow flexibility in changing between processes. For example: A gear can require peening with an S-70 in the root because of the size of the radius and an S-110 for the tooth. This can be processed in one step.

An integrated spiral separator is used to remove any out of round media. As media is used, it can crack or chip. If any shot breaks in half or chips instead of reducing in circumference in a balanced manner, it will scratch instead of peen. By integrating the separator, it ensures that the media being used to peen is spherical. An added benefit of more accurate abrasive delivery is the ability to hold tighter intensity tolerances.

Customized quick-connect tooling and nozzles are selected for the parts based on either bar code or part number. Once placed in the

machine, the tooling is verified by the systems integral computer. It uses RFID to ensure the proper tooling is in place and the correct media selection is made. Recipes and settings for each part are stored in the computer memory on the system with the peening parameters such as media type and pressure settings. As soon as each piece of tooling is in place, Almen Strips are run to develop a saturation curve and verify the peening process parameters. A saturation curve generator is stored in the system to make developing the saturation curve simple and convenient. Once the curve has been verified, the parts are placed in the tooling and the peening process begins.

APPLiCAtions overview Peening a ring gear used in an automobile planetary gear system is an excellent example of a shot peening application. It usually has a rounded groove profile, and to make the gear last longer, the bottom of that valley needs to be peened because its teeth are pushed back and forth; eventually, they are going to fatigue and break off into the valley. Shot peening gives them better fatigue life. Other applications require peening of the gear valley only to preserve the smooth tooth face, which can reduce noise.

Spur gears are also very common type of gear. They generally have straight teeth and transmit motion and power between parallel shafts, although they are not usually used in automobiles due to noise. Spur gears are used in many devices and industries, including: Electronics, construction equipment, machine tools, conveyors, and material handling. Spur gears may be shot-peened for both the root and teeth, or just the root.

Helical gears have teeth that are set at an angle. Because of this design, they can be more difficult to peen adequately using standard, wide blast systems. Helical and spur gears are very similar, except that the teeth of a helical gear are cut at an angle to the axis or hole. These teeth typically engage more slowly and smoothly than spur and other types of gears used for similar applications, because the load is transferred uniformly and gradually. This results in superior performance and reduced noise and vibration. When used on parallel shafts, helical gears are similar to spur gears, but generally provide a stronger, sm

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