refurbishing Wind turbine gearsAlteRnAtivesto Gear Grinding

Reducinggear Rattle

Site Safety tooth tipS hot Seat aGMa UpDateCompany profile: JLM Systems, Ltd.Cotta tranSMiSSion Co.

Q&a: matt mondek

gearsolutions.com

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see Whats Ahead

Your Future, Our FuturePredictive Process ControlThe NILES ZE Series has NEW features: High feed-rate grinding, Module 25 (1 NDP), High-speed measurement for full contact grinding.KAPP Technologies 2870 Wilderness Place Boulder, CO 80301 Phone: (303) 447-1130 Fax: (303) 447-1131 kapp-coburg.de | niles.de | kapp-usa.com kapp-asia.com | kapptec.com info@kapp-usa.com

28Refurbishing Wind Turbine GearsBy Mark Michaud, Gary J. Sroka, and Ronald E. Benson

featuresCompany Profile: JLM Systems, Ltd.

Isotropic superfinishing represents a value adding, low cost option for refurbishing both case carburized and nitrided gears.

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By Russ Willcutt

Developer of OILMISER technologies, this company provides clean and efficient fluid handling devices to customers found around the world.

Alternatives to Gear Grinding

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By Sanjai Keshavan

Honing and cup wheel superfinishing can be a costeffective and higher-quality alternative to gear bore and face grinding. Nagel Precision provides the details.

Reducing Gear RattleBy Mikel Janitz

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The professionals at Muncie Power Products help you to addressand eliminategear noise/rattle one step at a time.

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ResourcesMACHINES

MARKETPLACE

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

ADVERTISER INDEX

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Terry McDonald Many doctors believe that carpal tunnel syndrome is caused in the workplace by making repetitive motions without stopping periodically to stretch your muscles.

Site Safety

JUNe 2011 | VoLUMe 9 / No. 99 Gear Solutions (ISSN 1933 - 7507) is published monthly by Media Solutions, Inc., 266D Yeager Parkway Pelham, AL 35124. Phone (205) 380-1573 Fax (205) 380-1580 International subscription rates: $72.00 per year. Periodicals Postage Paid at Pelham AL and at additional mailing offices. Printed in the USA. POSTMASTER: Send address changes to Gear Solutions magazine, P.O. Box 1210 Pelham AL 35124. Publications mail agreement No. 41395015 return undeliverable Canadian addresses to P.O. Box 503 RPO West Beaver Creek Richmond Hill, ON L4B4R6. Copyright 2006 by Media Solutions, Inc. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopy, recording, or any information storage-and-retrieval system without permission in writing from the publisher. The views expressed by those not on the staff on Gear Solutions magazine, or who are not specifically employed by Media Solutions, Inc., are purely their own. All "Industry News" material has either been submitted by the subject company or pulled directly from their corporate web site, which is assumed to be cleared for release. Comments and submissions are welcome, and can be submitted to editor@gearsolutions.com.

William Crosher In the second installment of a three-part column, the author continues his outline of the evolution and continued development of hobs.

Tooth Tips Hot Jack Titus Seat

This month the author presents a discussion of the equipment used in the endo and low pressure carburizing processes.

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

Matt Mondek, president

Q&A

Cotta Transmission Co.

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American Gear Manufacturers AssociationIn 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. Letter ................................................................................................. 19 Association News ............................................................................ 20-21 Masthead ............................................................................................ 22

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Letter

From tHe

EDITOR

David C. CooperPuBlisheR

As president of the Cotta Transmission Company, Matt Mondek is a pretty busy guy. During our conversation for this issues Q&A I asked him why, despite his many responsibilities, he still feels its important to be involved in the AGMA, to which he was recently named chairman of the board. In addition to educational opportunities and helping develop industry standards, he pointed to the value of having fellow members as a resource when presented with professional challenges. If youre concerned about the integrity of your supply chain, for example, Matt could relate how Cotta and its vendors have helped each other through tough times, thereby strengthening an already longtime and mutually beneficial relationship. Or maybe youre thinking of expanding into a new market or region, in which case other AGMA members whove done the same might be willing to share their experience, allowing you to make a better-informed decision. My favorite comment, which youll read at the conclusion of this issue, is that AGMA members are just an awesome group of people. Speaking of which, an awesome group of contributors have stepped in to fill our pages with great information this month, beginning with Refurbishing Wind Turbine Gears by Mark Michaud of REM Surface Engineering and Gary J. Sroka and Ronald E. Benson of the REM Research Group. Mikel Janitz of Muncie Power Products has written Reducing Gear Rattle, helping you to addressand hopefully eliminategear noise and rattle. Sanjai Keshavan, of the ECO Hone Division of Nagel Precision Honing, has penned Alternatives to Gear Grinding, describing how honing and cup wheel superfinishing can be a great alternative to gear bore and face grinding. Dennis Gimpertpresident of Koepfer America discusses his plans as chairman of the AGMA Foundation in the associations special section, which also includes news of upcoming educational opportunities. My thanks go out to each of these individuals for their contribution to this issue, and especially to the gear manufacturing industry at large. Bill Crosher continues his discussion of the history and evolution of hobs and hobbing in this months installment of Tooth Tips, and Jack Titus describes the equipment used in the endo and low pressure carburizing processes in his Hot Seat column. Periodic stretching is encouraged as a means of avoiding carpal tunnel syndrome in Terry McDonalds Site Safety column, and JLM Systems is our company profile. Speaking with Dick Gangnon, the companys founder and president, for this piece made me recall a conversation I once had with the dean of a school of engineering, for which I produced a magazine. Asked to sum up the characteristics of an engineer in one word, my response was precision. Her reply? While thats certainly important, I think most engineers would choose efficiency. I feel that Dick would probably agree. In closing Id like to thank all of you who stopped by our booth last month at the American Wind Energy Associations WINDPOWER 2011 Exhibition & Conference in Anaheim, California. We were there to support Gear Solutions sister publication, Wind Systems magazine, and its always a pleasure to see our friends from the gear-manufacturing world who are also involved in the wind energy market. It was a great show, and just enough to whet our appetites for the AGMAs Gear Expo in Cincinnati next November. We look forward to seeing you there!

Chad MorrisonassOCiate PuBlisheR

Russ WillcutteditOR

eDitoriAL

Brad WhisenantnatiOnal sales manaGeR

sALes

Teresa CoopermanaGeR

CirCuLAtion

Kassie HugheyCOORdinatOR

Jamie Willettassistant

Jeremy AllenaRt diReCtOR

Art

Michele HallGRaPhiC desiGneR

Contributing writersROnald e. BensOn William P. CROsheR mikel Janitz sanJai keshavan teRRy mCdOnald maRk miChaud GaRy J. sROka JaCk titus Vertical Logo

Published by Media solutions, inc.P. O. BOx 1987 Pelham, al 35124 (800) 366-2185 (205) 380-1580 fax

David C. Cooper

Russ Willcutt, editor

PResident

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

Chad Morri sonviCe PResident OPeRatiOns

Teresa Cooper

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INDUSTRY NeWS

New Products, Trends, Services, and Developments

Sandvik Coromant Joins Commonwealth Center for advanced Manufacturing

Sandvik Coromant has united with the Commonwealth Center for Advanced Manufacturing (CCAM) as an originating industry member. Located in Prince George County, Virginia, the facility is specially designed to be a collaborative research center in which the member companies and academic partners can work together on R&D initiatives. CCAM will provide the industry with transformational improvements in advanced manufacturing technologies for surface engineering and manufacturing systems. Sandvik Coromant will be among some of the best industrial partners, OEMs, and suppliers from a broad range of industry sectors including aerospace, shipbuilding, nuclear, and electronics. These founding members include Canon Virginia, Inc., Chromalloy, Newport News Shipbuilding, Siemens, and Rolls-Royce. In addition, CCAMs academic members include University of Virginia, Virginia

Tech, and Virginia State University. This is an exciting venture for us, according to John Israelsson, president of Sandvik Coromant USA. This is our opportunity to shape the future of manufacturing technology by collaborating with diverse industry sectors with similar problems as well as to have access to resources for combined development work.

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

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In the accompanying photo youll find (top row, left to right) Peter Diakun, vice president and chief technology officer, Newport News Shipbuilding; William Powers, executive vice president and CFO, Rolls-Royce North America; David Lohr, president and executive director, CCAM; Armand Lauzon, president and CEO, Chromalloy; Don Leo, Ph.D., associate dean of research and graduate studies, Virginia Tech; Robert Shenton, VP and COO, Aerojet. In the bottom row (left to right) is found Dr. John Sparks, director of engineering and technology programs, Aerojet; Dr. Charles Steger, president, Virginia Tech; Barry Johnson, senior associate dean and associate dean for research, University of Virginia; Dr. Teresa Sullivan, president, University of Virginia; Bob McDonnell, governor of Virginia; Ron Briggs, vice president of the administration group, Canon Virginia Inc.; Andreas Saar, vice president of component manufacturing solutions, Siemens PLM Software; John Israelsson, president of Sandvik Coromant USA; and Dr. Keith

Miller, president, Virginia State University. To learn more about CCAM go to [www. ccam-va.com]. Visit Sandvik Coromant at [www.sandvik.coromant.com/us].

SMes tooling U Relocates to Brick and Mortar SiteTooling U, the leading developer of online manufacturing training, has relocated its headquarters to Tyler Village, which is one of Cleveland, Ohios, largest downtown redevelopment projects. Following the Society of Manufacturing Engineers acquisition of Tooling U last fall, a search began for a new location that allowed for continued expansion. Manufacturing is leading the recovery, and manufacturers are in greater need of training their employees, says Chad Schron, Tooling Us division manager. In order to support Tooling Us e-learning offerings, we needed to expand our brick and mortar offices. Only six miles from its previous office, Tyler Villagea former industrial complex and now a thriving, mixed-use business

complexfit the needs of the growing company. Our bread and butter is manufacturing, Schron says. We like the story that we've repurposed this space for a high-tech application. We like the unique atmosphere, and the location is still accessible for our employees. The 8,000 square-foot site has already enabled Tooling U to add additional writers, support staff, and customer success managers, which led to the launch of a new composites training curriculum. Tooling U provides training for operators in the automotive, aerospace, defense, medical, and oil and gas sectors. It also works with corporations such as General Electric, Caterpillar, and Harley Davidson as well as small and mid-sized companies and technical and community colleges. Tooling U allows operators to take classes 24/7 in a host of manufacturing topics. Classes are interactive, include both audio and video components, and provide one-on-one, synchronous training. For more information about Tooling U, e-mail info@toolingu.com or visit [toolingu.com]. Learn more about SME at [www.sme.org].

Congressman Visits overton Chicago Gear

Overton Chicago Gear (OCG) recently had the pleasure of meeting their Illinois representative. Congressman Peter Roskam, of the 6th District of Illinois serving Addison and Lombard, visited the facility on April 27, 2011. He is a member of the Ways and Means Committee and known as an advocate of ESOP companies. Roskam was interested in hearing about the strength of the industrial manufacturing sector in his district. OCG shared

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their continued success in the manufacturing of gears and gearboxes, even with the challenges of foreign competition and challenging economic conditions. Everyone at OCG thoroughly enjoyed the visit and looks forward to future visits to their facility. For more information go online to [www.oc-gear.com].

Spinelli, Jr. As a model for professional university education, Philadelphia University is focused on innovation. The careers and successes of our honorees across a range of disciplines inspire us. They are not only accomplished in their fields, but they also exemplify the universitys mission, sense of purpose, and innovative spirit. In addition to its collaboration with

Philadelphia University, MAG supports student apprenticeships with salaries and 100-percent tuition, working through local community and technical schools around the world. The company also invests aggressively in internal leadership development for promising management candidates. Founded in 1884, Philadelphia University

MaG Chairman Receives Leader of innovation MedalMAG IAS, LLC Chairman and CEO Dr. Eng. Mo I. Meidar received a Leader of Innovation Medal from Philadelphia University at its Spirit of Innovation Gala April 30. Also honored were Jose Maria Alapont, president and CEO of Federal-Mogul Corp.; Dorothy Roberts, chairman of The Echo Design Group; and Tomio Taki, managing member of Takihyo LLC. According to Philadelphia University, the Leader of Innovation Medal recognizes creative entrepreneurs who have made significant contributions across many fields that better society and shine a light on the impact of innovation. Meidars company, MAG, is the worlds leading developer of automation technologies for producing composite structures for aerospace, automotive and wind energy. The company is also one of the largest global suppliers of machine tools and automated manufacturing systems for the durable goods industry. MAG has manufacturing and sales operations around the world. Meidar is an alumnus and trustee of the university, who has given great support both intellectually and materially. MAG recently funded the new Philadelphia University MAG Composites Institute and has donated a machining center to be used by students in manufacturing of engineering prototypes. Its an honor to be recognized with such a distinguished group of achievers as represented by this years award recipients, Meidar says. MAG enthusiastically supports the work of Philadelphia University in its development of the next generation of leaders in manufacturing, engineering and other fields. We want them to have every competitive advantage possible as they launch their careers. These friends and alumni are worldclass leaders and innovators, according to Philadelphia University President Stephen

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Siemens Wins order for New off-Gas Monitoring SystemSiemens Industry, Inc., has received an order to provide an electric-arc-furnace (EAF) off-gas monitoring system at Steel Dynamics Roanoke Bar Divisions mini mill in Roanoke, Virginia. This order marks Siemens VAIs expansion of its patented continuous off-gas sampling and analyzing system (LOMAS) into electric-arc-furnace process optimization through continuous offgas monitoring. It is already a market leader for such technology in basic oxygen furnaces (BOF). By continuously monitoring the EAF off-gas analysis and offgas flow, and by utilizing the measured values with a SIMETAL holistic process model, this system provides instant feedback from the process and gives guidance for users to make adjustments as needed. Process inefficiencies can then be corrected by a closed-loop control for natural gas and oxygen injection through burners and lances. Consequently the technology results in reductions of overall energy, electrode, and jet-oxygen and burner-gas consumption, as well as augmented metallic yield and productivity. The LOMAS system also offers increased operational safety attributes due to its ability to quickly detect dangerous gas compositions during the melting and refining process. Greenhouse gas emission control is an added environmental benefit. The decision to install the LOMAS system was based

is a private university with 3,500 students enrolled in more than 60 undergraduate and graduate programs. Go online to [www. philau.edu]. MAG is a leading machine tool and systems company serving the durable goods industry worldwide with complete manufacturing solutions for metal cutting and composites applications. Learn more at [www.mag-ias.com].

408.723.0700

270 Hillsdale Avenue | San Jose, CA 95136 Fax: 408.723.0710 E-mail: info@ws2coating.com

www.ws2coating.com12 gearsolutions.com

on Siemens extensive experience and success with off-gas monitoring in BOF shops, says Paul Schuler, manager or melt and cast at SDI Roanoke. This experience and their desire to bring off-gas analysis to EAF shops gave us confidence that Siemens state of the art system would allow us to monitor and control in real time our process efficiencies, which we expect to reduce costs, increase productivity, and improve safety in the melting process. Siemens Industry, Inc. (SII) is the U.S. affiliate of Siemens global Industry Sector businessthe worlds leading supplier of production, transportation, and building technology solutions. The companys integrated hardware and software technologies enable comprehensive industry-specific solutions for industrial and infrastructure providers to increase their productivity, sustainability, and profitability. Go online to [www.usa.siemens.com/ industrysolutions].

system with a new, state of the art CNC control system. New digital servomotors and drive amplifiers are properly sized to match the machines capabilities. A new operators pendant and magnetic panel typically accompanies a complete retrofit. Additionally, all existing wiring is removed from the machine and replaced with new. Konecranes has assembled some of

the most talented and experienced applications engineers in North America. They are experienced and capable of performing control retrofits using a variety of CNC & PLC controls. Konecranes has the experience to work with modern PC-based control products. Many CNC control systems will allow for reuse of some of the existing drives,

Konecranes Machine tool Service offers RetrofitsKonecranes Machine Tool Service has extensive experience integrating numerous makes and models of CNC and PLC controls to a variety of complex and conventional machines, including but not limited to gantry mills, horizontal boring mills, vertical boring mills, machining centers, grinders, turning centers. and specialty machines. In todays competitive marketplace, manufacturers are challenged to produce more precise parts in a timely manner and at an affordable rate. Many manufacturing companies are leveraging their competitive advantage via CNC controls, servomotors, and drives retrofit from their existing machinery. When properly engineered a new CNC control retrofit can increase productivity significantly, reduce the cost of energy, and improve mean time between failure rates. The group is a recognized leader in the CNC control retrofit business. Konecranes control retrofits allow customers to sustain their competitive edge in the global marketplace. After inspection a CNC control retrofit performed by Konecranes may include replacing the existing antiquated control

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motors and wiring, thereby reducing the cost that is typical with a complete retrofit. If a machine is mechanically sound but suffers from control related failures due to age or other performance deficiencies, it may need a control-only retrofit. Konecranes will work with the customer to discuss value priced options such as upgrading controls, without the expense of replacing the existing servo motors and drives. For more information go to [www.mtsunlimited.com] or [www. konecranesamericas.com].

Mazak plans technology Center expansionThe continued upswing in business in the Midwest has spurred plans for expansion at Mazaks Midwest Headquarters and Technology Center located in Schaumburg, Illinois. The expansion represents Mazaks continuous investment in American manufacturing and coincides with other recent investments, including a new facility in Houston and production expansion at its manufacturing campus in Florence, Kentucky, to meet customer demand. The vibrant manufacturing market and our long-term commitment to customers in the Midwest convinced us to accelerate our expansion plans of our Technology Center in Illinois, says Brian Papke, president. In line with our new Southwest Headquarters and Technology Center in Houston and a new $9 million investment in our Kentucky plant, the goal of the Midwest expansion is to continuously serve our customers with solutions for improved manufacturing productivity to competitiveness of North American manufacturing. Mazak plans to move quickly on the Midwest expansion project, with a grand opening targeted for April 2012. The expanded facility will feature a new auditorium space, more room for seminars, and a spacious area for customer turnkey projects and test cuts, as well as expanded machine tool technology demonstration facilities. The company will keep customers up to date on the latest details of this and future investments via its social media outlets and Web site. Mazak Corporation is a leader in the design and manufacture of productivity-improving machine tool solutions. Committed to being a partner to customers with innovative technology, its world-class facility in Florence, Kentucky, recently initiated a $9 million manufacturing expansion. The facilitys production on demand manufacturing concept uses the latest in machine tool technologies as part of its lean strategy. Mazak maintains eight Technology Centers across North America to provide local hands-on applications, service and sales support to its customers. For more information visit [www.mazakusa.com].

LMS expands test.Lab transfer path analysis portfolioMarket leader LMS International offers the most complete portfolio of transfer path analysis (TPA) solutions available. Built on more than 30 years of continuous research and development work, LMS TPA methods are the problem-solvers of choice for noise and vibration engineers in the worlds

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leading manufacturing industries, including practically every major automotive OEM. What the market appreciates is our hands-on and comprehensive approach to transfer path analysis, says Bruno Massa, vice president of the test division at LMS International. We listen to our customers and help them implement the right techniques for the variety of noise and vibration problems they encounter. A top example in our TPA portfolio is our patented LMS Test.Lab OPAX technique. Using its wider frequency range for increased accuracy, engineers can quickly identify the root causes of noise and vibration issues faster than ever before. Plus, the depth of our portfolio means that there is a TPA solution to tackle all kind of issues from every possible angle. In complicated structures with various sub-assemblies such as cars, aircraft, or ships, vibro-acoustic phenomena at a certain location may be caused by a remote vibration source. For example, the energy from a car engine is transmitted into the passenger cavity by a number of different routes: from the engine mounts, the exhaust system connection points, and even indirectly via the drive shafts and the wheel suspension. These complex noise and vibration issues can be thoroughly examined using enhanced TPA techniques to help engineers detect root causes early in the design cycle. LMS Test.Lab provides a highly efficient solution to identify unwanted noise and vibration, trace it back to its origin, and quickly evaluate design improvements. As a systematic approach for any test-based engineering process, TPA is a valuable time-saving method that helps engineers set the right brand-critical

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noise and vibration performance targets on both the full system and component levels, Massa says. With an optimized product development cycle, engineers actually pre-design the ideal components to avert undesirable noise and vibration. On the other hand, TPA remains a popular method for troubleshooting existing vibroacoustic issues, and is rapidly spreading

from its core application area in automotive to other manufacturing industries, such as white goods, office equipment and even aviation and shipbuilding. A pioneer of transfer path analysis, LMS commercialized the first TPA product in the early 1990s under the LMS CADA-X platform. Today this know-how is baked into the market-leading LMS Test.Lab solu-

tion. Obtain more information at [www. lmsintl.com].

industry Glossary on fMa Communications Web SiteFMA Communications, Inc., announces the addition of a comprehensive industry glossary to its Web site. The glossary currently lists over 570 industry terms with an estimated expansion to over 3,200 entries. Glossary terms are also listed in the articles on the site so visitors can learn more about a particular term. The goal is for the glossary to be the largest and most comprehensive available online in the industry. The glossary is a tremendous tool for newcomers to the metal forming and fabricating industry, says Jim Gorzek, associate publisher of FMA Communications. Visitors can now find a quick definition and then look for more in-depth knowledge using thefabricator.coms robust search capabilities. The metal forming and fabricating industrys leading online resource, thefabricator. com attracts more than 120,000 unique visitors every month who are looking for articles, news, and products they need to operate and grow their businesses. Thefabricator.com adheres to the same editorial standards as all publications from FMA Communications, and content is divided into tech cells that allow visitors to zero in on their areas of interest. FMA Communications, Inc., the publishing affiliate of the Fabricators & Manufacturers Association, currently serves the metal forming and fabricating industry by publishing business-to-business magazines, e-newsletters, vendor directories, and Web sites. FMA is a professional organization with more than 2,100 members working together to improve the metal forming and fabricating industry. Founded in 1970, FMA brings metal fabricators and fabricating equipment manufacturers together through technology councils, educational programs, networking events, and the FABTECH show. FMA also has a technology affiliate, the Tube & Pipe Association Intl. (TPA), which focuses on the unique needs of companies engaged in tube and pipe producing and fabricating. Go online to [www. thefabricator.com/glossary].

At Forest City, We Always Have Gears On Our Minds...Some folks might think a diametral pitch is a roundabout way of selling something, but we know better at Forest City Gear. Our gearheads live with the math and physics of gears on their minds, every day. Plus, they bring an unmatched knowledge of materials and CNC machine tool functionalities to the difficult task of making the world's very best gears, to exacting customer specifications, time after time after time. In our world, you see, consistency is not the hobgoblin of little minds, with all apologies to Mr. Emerson (the essayist, not the electric motor magnate). Doing something right "most" of the time simply isn't good enough at Forest City Gear, as it isn't for our customers. They demand we make it right, every time, as our products help their products perform better. As a result, their reputation rides, in part, on ours. This is a very special trust and we do our best to preserve it, all the while trying to improve the products we deliver. We do this by maintaining a machine shop that's the envy of the gear world, from the first drawing to every step in the machining process to the final inspection in our state-of-the-industry QC department and finally, to the careful product handling and packaging. For a sample of how good a gear company can be, when they maintain such "top of mind awareness" for customers, check out www.forestcitygear.com. We'll be thinking about you.

Gearheads? You Betcha.11715 Main Street, Roscoe, IL 61073 815-623-2168

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Forest City Gear Ad4806 Island GearHeads Gear SolutionsBernard & Company 12/14/10

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a Green alternative to fluid Disposal from QuakerQuaker Chemical offers its customers a greener alternative for the disposal of used process fluids. By recycling and reusing many of the process fluids utilized in a metalworking facility, Quaker helps its customers to lower their costs and lessen their environmental impact. When automotive production declined in the later part of 2008, many manufacturers found it necessary to decommission machines. Rather than dispose of unused process oils and lubricants, Quaker helps its customers to recycle these fluids by capturing them and either transferring them to other lines, to other facilities, or reformulating them for use in completely different processes. The result can be significant cost savings, not only in terms of waste disposal, but also as related to buying new virgin materials. For example, Quaker assisted one automotive manufacturer to recycle almost 15,000 gallons of straight oil from a machining operation and reuse within the facility, resulting in almost $100,000 of direct savings to the customer. In another instance Quaker took hydraulic fluid from a decommissioned machine and transferred it for use at another of the customers facilities, saving the customer around $20,000. Yet another example is when Quaker worked with an automotive manufacturer to convert obsolete material to meet the specification of a straight oil used for broaching, saving the customer almost $10,000. In addition to hard cost savings, there are the obvious environmental benefits to the recycling of metalworking process fluids. When a customer hires Quaker to manage the chemical specialty products in their facility, we do this through the entire life cycle of the chemical, including disposal, says Kyle Campbell, senior director of metalworking and services in North America. Its our job to educate and counsel our customers on how to get the most value from their metalworking process fluids, which sometimes includes recycle and reuse versus disposal. This may not always be the best decision for Quakers bottom line, but we are focused on making the best decision for our customers' bottom line.

Quaker Chemical Corporation is a leading global provider of process chemicals, chemical specialties, services, and technical expertise to a wide range of industries including steel, aluminum, automotive, mining, aerospace, tube and pipe, coatings, and construction materials. Quakers products, technical solutions, and chemical management services enhance customers processes, improve

product quality, and lower costs. Learn more at [www.quakerchem.com].

heat treating Sheets from precision Brand productsPrecision Brand Products introduces a safer, more economical alternative to the standard tool wrap rolls, 12 x 24 type 321 heat treating sheets. The sheet design keeps handling to a minimum. The 12 x 24

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sheet size has been tested and chosen to be the optimum size to accommodate the vast majority of parts, especially those heat-treated in small bench type furnaces. Individual sheets are easy to access and fabricate, requiring one cut or less to form into a usable heat-treating envelope for the part. Less handling means less risk of being cut. The new 12 x 24 sheets are convenient-

ly packaged for easy handling and storage. The unique package allows for easy access to each individual sheet and protects from dirt and damage during storage. Excess material can be conveniently stored flat in the box. Packaged in convenient 10, 20, or 30 sheet packages, there is a quantity for every size, shop, or lab. The sheet design means less waste from excess handling and improved product performance. For

more information call (800) 535-3727 or visit [www.precisionbrand.com].

enhanced Non-Contact tube inspection Systems from RoMeRROMERa brand of Hexagon Metrology, Inc.announces their new line of noncontact tube inspection systems. The enhanced product line provides solutions for a wide array of tube and wire bending applications including tube inspection, bend correction to reduce scrap, reverse engineering, and fixture verification. System enhancements focus on expanded flexibility, simplicity, and ease of use to increase shop productivity. New to the system, a range of noncontact infrared probes provide operatorassisted visual notification via a laser stripe indicating the measured area. The operator can view where data points are acquired on a tube or wire during the inspection process. The probes are interchangeable with traditional ball probes without the need for re-calibration, delivering true plug and play capability. Brackets, flanges, bosses, or other geometric features can now be included in the measurement routine. Besides saving time, no recalibration also provides an additional layer of error proofing in the field. As with ROMERs legacy systems, the non-contact probing feature enables measurement of the most flexible tubes or wires from 4mm to 130mm in diameter, without risk of deflection. Zvonimir Kotnik, director of the business management group of Hexagon Metrology, sums up the new tube inspection product line. The straightforward operation of the overall system guarantees simple, flawless operation. By making the measurement process easier for the operator, we have improved efficiency, accuracy, and productivity for the entire tube shop. ROMERs tube inspection system is based on the patented ROMER Absolute Arm portable CMM. Proprietary absolute encoders are located in the arms primary axes, so the arm always knows the position of its joints. This eliminates antiquated homing procedures, so the operator can turn on the system and Continued on pg. 58 >

the premier gear manufacturer for Aerospace, defense, industrial and Automotive industries. Delta Gear products are recognized around the world for precision-quality and on-time delivery. now we have the privilege of taking the tiFCo Gage & Gear legacy of products forward with us into the future. together, our superior manufacturing capabilities, highly trained workforce and ability to manufacture highly engineered and customized products set us a part from all the other aerospace gear manufacturers. our continuous capital investment in precision CnC machinery, trained personnel, iSo9001 and aS9100 registrations, non-destructive testing and engineering solutions deliver aerospace quality at automotive prices.

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American Gear Manufacturers Association

Looking Ahead: The AGMA Foundations FutureDuring the 2011 AGMA/ABMA Annual Meeting, I began my three-year term as chairman of the AGMA Foundation. As we move forward I would like to share some of my thoughts on what I feel our foundation is, and where it should be going. The AGMA Foundation was originally organized in 1994 as a non-profit 501(c) (3) charity. The foundations legal structure allows companies and individuals to make fully tax-deductible contributions. The original mission of the foundation was to facilitate special financial funding of AGMAs ISO standards work.The mission was later broadened to include funding of educational and research projects in addition to the ISO and standards work. The current vision statement for our foundation is: Excellence in gearing through the advancement of gear science, standards and education, and our current mission statement is: To support the establishment of global gear standards, research to strengthen those standards and training and education to ensure their effective use. Some of the recent projects that the AGMA Foundation has supported include: Creation of a web-based version of AGMAs Detailed Gear Design program. Establishment of a scholarship program to financially assist graduate level engineering students whose programs focus on gear technology or gear research. Funding of a research program at Ohio State UniverUniver sity on Prediction of Micropitting. Funding of research at the Gear Research Institute on Gear Noise and Vibration Documentation. This summer the foundation board of trustees will meet at the AGMA headquarters in Alexandria, Virginia, to conduct a strategic planning session. Our goal will be to organize our vision and priorities in response to both our dynamic global environment and the changing desires of our donor base. Our strategic planning process will lead us to specific priorities, the building of a commitment to those priorities, and the planning for allocation of resources. In its final form the strategic plan will provide a blueprint for annual and future actions. We will ensure that our donorswho are mostly AGMA memberswill be effectively represented and served. Prior to this important strategic planning session, trustees from your AGMA Foundation board will be contacting selected individuals for a brief telephone interview. We hope to build a closer relationship with our supporters and learn your specific interests and needs. We look forward to receiving your input and suggestions. Beginning this summer, the foundation trustees and other volunteers will begin our annual fund-raising drive. They will be contacting both you and your companies to ask for financial contributions. It is important to note that these funds are used for foundation purposes, either with current or future projects, as well as building a permanent endowment fund. Also, you as a member have the opportunity to submit ideas for worthy projects as well as to participate in the scholarship program.

Dennis Gimpert chairman AGMA Foundation President, Koepfer America (703) 684-0211 www.agmafoundation.org

Detailed Gear Design Online!

AGMA has taken one of its most popular courses out of the classroom. Detailed Gear Design: Beyond Simple Service Factors is now available online in a course offering of 15 one-hour video segments. Get the same great lectures and course materials from renowned gear educator Raymond Drago at the convenience and privacy of your own personal computer. AGMA recognizes that its members need high quality advanced gear education, but the organization also recognizes that schedules, transportation costs, time out of the office, and learning styles may hamper students from attending the classroom versions of courses. In providing Web alternative learning opportunitiesdigital courses and webinarsAGMA hopes to fulfill needs of members on a more-broad basis. Detailed Gear Design: Beyond Simple Service Factors begins with a discussion of the true aim of gear design and brings into focus many of the often-conflicting considerations of designing gears to meet specific customers expectations. Cost, reliability, safety, liability, and the possible consequences of failure are just some of the factors that are covered in this course. How do we optimize a gear? How do we get the most capacity out of a gear? These questions and more are answered in this course.

Course Outline1) Basic introduction to gear rating theory and standardized AGMA/ISO analyses methods including theoretical models for strength, durability, wear, and scoring hazard. 2) Practical considerations and limitations associated with the application of standard AGMA/ISO durability rating analyses: The theoretical surface contact stress model and its application to gear tooth contact conditions. 3) Investigation of the differences in stress states among the various surface durability failure modes including pitting, spalling, case crushing, and subcase fatigue. 4) Extended load capacity analysis techniques (beyond the AGMA/ISO standard methods) including: Subsurface shear stress analysis for the determination of optimum effective case depth and relation to subcase fatigue and case crushing. Conversion of subsurface shear stress profile into required subsurface hardness profile.

Calendar of Events** Event open to AGMA members only. Not a member? Send e-mail to membership@agma.org.

Whether 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 e-mail to events@agma.org.

WebEx WebEx WebEx WebEx 1:00 2:30 pm EDT

June

1

Mill Gearing Committee Meeting

7

Helical Gear Rating Committee Meeting

9Energy Efficiency 14

14

Enclosed Drives for Industrial Applications Committee Meeting

15

AGMA Webinar SeriesConditions for Cutting Tools

Cutting Tools Committee Meeting

7-8

Wind Turbine Committee Meeting

14-15

Plastics Gearing Committee Meeting

21-22

Helical Enclosed Drives High Speed Units Committee Meeting

Alexandria, VA

WebEx Chicago, IL Hartford, CT

gearsolutions.com

5) Consideration of friction in the calculation of surface compressive stresses: The relation between pure Hertz-type compressive stress and pitting. The relationship between spalling and the occurrence of a combined tension and compression state at the tooth surface due to mesh friction effects. 6) Practical considerations and limitations associated with the application of standard AGMA/ISO strength rating analyses. 7) The theoretical strength stress model and its application to gear tooth bending stress evaluation: Correspondence between calculated stress numbers and actual measured tooth root stresses. 8) The effect of gear blank rim thickness on the tooth root stress state: Rim bending participation. The rim thickness factor, development and limitations. 9) Discussion of differences between fatigue, time dependent, and time independent failure modes as related to gear tooth design: Durability and strength. Wear. Scoring. 10) Wear evaluation by the application of elastohydrodynamic analyses Basis of the analysis development. Probabilistic nature of wear evaluation. Time dependent, non-fatigue nature of wear progression. Self propagating mechanism.

11) Scoring Hazard evaluation by the application of Bloks Critical Temperature theory: Basis of the analysis development. Probabilistic nature of the problem. Time independent nature of failures. 12) Optimization of gear tooth detail design parameters including: Considerations for minimum roll angles. Effect of and design for specific sliding (slip ratio) and entraining velocity. Stress balanced or life balanced gear pinion and gear relative design. Influence of geometric characteristics such as tooth top land, tooth thickness, etc., on optimized tooth design. 13) Considerations of fillet geometry in the avoidance of fillet interference and excessive stress concentrations due to adverse fillet geometry. Computer generated animated graphics will be used for examining mesh action and tooth interaction. Each section discussion will be followed by a brief question and answer period. The registration fee will include all meeting materials, scheduled meal functions, and an opening evening networking reception. A certificate will be awarded to each attendee.Jan Alfieri, AGMA Education Manager

Providence, RI WebEx WebEx Alexandria, VA

23 Committee Meeting 27-29Gear Failure Analysis Seminar

Fine Pitch

July

12

Spline Committee Meeting

19

Helical Enclosed Drives Marine Units Committee Meeting

26-27

Sound & Vibration Committee Meeting

14

Helical Gear Rating Committee Meeting

20-21

Powder Metallurgy Committee Meeting

WebEx Big Sky, MT

Available Year-Round

Online Workforce Education

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

JANUARY 2010

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AGMA Announces Fall Education ScheduleGear Failure Analysis SeminarSeptember 19-21, 2011 Big Sky Resort, Big Sky, MT

AGMA is looking forward to an education-packed fall season. Registration is now open for the following events at [www.agma.org].

Gear Manufacturing & Inspection: Methods, Practices, Application & Interpretation for the Design EngineerOctober 18-20, 2011 Cleveland, OH

Avoid gear failure and save thousands of dollars in repair costs by knowing what causes gear failure and how to prevent it from occuroccur ring. This course is a perennial sellout and is limited to 30 students, so register soon. Students will examine the various types of gear failure such as macropitting, micropitting, scuffing, tooth wear, and breakage. Possible causes of these failures will be presented, along with some suggested ways to avoid them.

Basic Training for Gear ManufacturingOctober 3-7, 2011 Chicago, IL

In this seminar students gain a broad understanding of the methods used to manufacture and inspect gears, and more. The course takes the process one step further, teaching how the resultant inforinfor mation can be applied and interpreted in the design process. This seminar aims to narrow and possibly close the information gap by providing gear design engineers with a good foundation in both manufacturing and inspections processes and procedures.

Gearbox System Design: The Rest of the StoryEveryStoryEvery thing but the Gears and Bearings!December 6-8, 2011 Clearwater, FL

The AGMA Training School for Gear Manufacturing will enable students to become more knowledgeable and productive. The Basic Course teaches participants to set up machines for maximum efficiency, to inspect gears accurately, and to understand basic gearing. Although the course is designed primarily for newer employees with at least six months experience in setup or machine operation, it has proved beneficial to quality control managers, sales representatives, management, and executives.

This program addresses what gear engineer can do to optimize the gearbox system, from the housings to the lubrication and much more. The seminar starts with the basics: history of design, the environment in which the gearbox must live and the loading to which the system will be subjected in service. Loading includes starting/ stopping, continuous, reversing, cyclic and possible errant loads conditions.

AGMA LeadershipBoard of DirectorsNorbert Benik: VP of Industrial Sales, Ontario Drive & Gear, Ltd. Jim Bregi: President, Doppler Gear Company Sulaiman Jamal: Managing Director of Bevel Gears (India) Private Limited Tom Marino: President & CEO, Gear Technology Gordon New: Managing Director, Ronson Gears Pty, Ltd. Bob Phillips: Senior Vice President, Gleason Cutting Tools Corp. Bob Sakuta: President, Delta Gear Kyle Seymour: President & CEO, Xtek, Inc. Mike Smith: Vice President of Sales and Marketing, Capstan Atlantic Mike Suter: Vice President of Marketing, Emerson Industrial Automation Dirk Wernecke: Global Manager, Pricing, The Timken Company

Executive Committee

Chairman: Matt Mondek President, Cotta Transmission Company, LLC Treasurer: Louis Ertel President & CEO, Overton Chicago Gear Corp. Chairman, BMEC: John Strickland VP of Marketing and Strategic Planning, Fairfield Manufacturing Co., Inc. Chairman, TDEC: Dr. Phil Terry Chief Metallurgist, Lufkin Industries Chairman Emeritus: Dave Ballard Director of Marketing & Business Development, North & South America, Siemens Industry, Inc.

Staff

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

Contact the AGMAwww.agma.org gearsolutions.com

General requests: webmaster@agma.org Membership questions: membership@agma.org Gear Expo information: gearexpo@agma.org Technical/Standards information: tech@agma.org AGMA Foundation: foundation@agma.org

500 Montgomery Street, Suite 350 Alexandria, VA 22314-1581 (703) 684-0211

Weve all seen people Wearing those braces on their wrists that extend from the knuckles to midway up the forearm, and most of us know someone whos had to wear oneif we havent had to, ourselves. While some might be the result of a tennis injury or something along those lines, most often theyre being used to treat something known as carpal tunnel syndrome, or CTS. Although doctors have different theories, most agree that CTS is caused by repetitive motion such as typing on a keyboard for many hours each day or performing the same physical motion in the workplace. Steady pounding and constant vibration have also been cited as possible causes. What happens is that the median nerve passes through the carpal tunnel in your wrist,

SITESafetyterryMcDonALDMember of the ANSI Subcommittee on Gear Safety

Many doctors believe that carpal tunnel syndrome is caused in the workplace by making repetitive motions without stopping periodically to stretch your muscles.

Carpal tunnel syndrome gets more painful as it progresses, and you can even experience weakness in your hands, which can really cause problems for people who work in manufacturing.

and when the surrounding tissue begins to swell it presses against the nerve, and with no way to relieve the pressure within the carpal tunnel you begin to experience pain and numbness in your hands. And, yes, it seems to be another one of those complaints that you need to protect yourself against even before it starts hurting, which can be difficult to do without that painful reminder. Many doctors think the damage is cumulative, so it just seems to get worse once the aching begins, and wrist braces cant do anything about the damage thats already been done. They mostly serve to immobilize the wristand to remind you to take a break every now and then. you want to keep your hands in motion. I sometimes think that there seems to be more people getting migraine headaches these days, and ABOuT THE AuTHOr: Ive often wondered if it doesnt have something to Terry McDonald is partner and manager of Repair Parts, Inc., and a member and do with all the time we spend staring at a computer pastchairman of the ANSI B11.11 Subcommittee on Safety Requirements for screen, sometimes only a foot or two away. They Construction, Care, and Use of Gear Cutting Equipment. Contact him at (815) say that if you do that type of work you should take 9684499, rpi@repairpartsinc.com, or [www.repairpartsinc.com]. a break once an hour or so and stare off into the

distance so that your eyes can adjust. Thats good advice for people who perform a repetitive motion with their wrist all day, too, like working on an assembly line or some type of manually operated machine like a drill press. It can be hard to find the time to do it when youve got a schedule to keep, but its important to stop what youre doing periodically and stretch your wrist into positions that are different from those youre doing in your work. By gently flexing your wrist backwards and forwards, then to the sides, and repeating that motion, you should feel your muscles begin to limber up, and hopefully they wont start getting stiff as quickly once youve resumed your work. Like Ive said, though, its a good idea to go ahead and get in the habit of doing this before you start experiencing pain. Its called being proactive, and thats always a good idea. In case youve been feeling pain in your wrist and wondered what it was, the symptoms involve tingling and numbness at the base of your fingers and in your wrist in the early stages. It gets more painful as it progresses, and you can even experience weakness in your hands and a loss of grip strength, which can really cause problems for people who work in manufacturing. While machines are more automated than ever, there is still plenty that has to be done by hand, so losing the ability to grip tools and controls firmly is something you definitely want to avoid. If youre involved in this type of work and are experiencing these feelings in your hands and wrists, you need to pay your doctor a visit where they can diagnose CTS fairly easily. If you do have it treatments can involve everything from steroid injections, to occupational therapy, to the immobilizing wrist braces Ive already mentioned, to a procedure called carpal tunnel release surgery. The good news about the surgery is that it has a 90-percent success rate, with people able to go back to their jobs after a short period of recuperation. The bad news is that its still surgery. Like Ive said, doctors arent in agreement about what causes carpal tunnel syndrome. Some think its genetic, while others feel that its a result of repetitive motion. Whatever the cause, statistics show that one in 10 people will develop CTS at some point, and those who do will end up shelling out about $30,000 for treatments and surgery during their lifetimes. So stop and stretch periodically if

JUNE 2011

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

In the second installment of a three-part column, the author continues his outline of the evolution and continued development of hobs.

An alternate to the use of a hob is a fly tool, and they are frequently used in the cutting of a worm wheel with tangential feed. This method has none of the irregular flank contours that are present when a hob is used. The simple tool is reasonably easy to make, and it reduces the tooling cost when manufacturing small quantities of high-precision special gear forms. Hobbing is five times faster than fly cutting, but hobs are much more expensive.

TangenTial feed hobs are in Three basic designs: pancake, multiple-spiral cylindrical, and pineapple. The former are low in cost with a narrow face and a minimum of cutting edges, wear rapidly, and have longer cutting times. Globoidal worms can be produced on a standard hobber by reversing the location of the cutter or bladed cutter assembly with that of the gear blank. The cutter is fed radially into the blank to produce the form. To obtain maximum benefit after the hob is fed to the proper depth, the gear blank must be rotationally advanced and retarded for a trimming cut on each flank. The mating gear is for all practical purposes impossible to cut by conventional methods.

ACCurACy grADesHobs are available in five accuracy grades: Class AA-Ultra Precision Ground; A-Precision Ground; B-Commercial Ground; C-Accurate Unground and; D-Commercial Unground. The tolerances for Class AA were established by the Barber-Colman Company, and the others by the Metal Cutting Tool Institute. The hob accuracy has a direct relationship with the quality of the gear being produced. The hobs cutting edges maintain the correct pressure angle and lie along a helix with the established lead. A Class AA will be capable of producing an AGMA A5 (Q12) gear, and if Class B an AGMA A7 (Q10) gear when the hob has an adequate number of gashes, was properly mounted, and their tolerances maintained after sharpening. Hobs are form-relieved cutters. They are sharpened by grinding the faces of the hobs teeth to the bottom of the flute. Errors frequently arise after the hob has been sharpened. A consistent amount of metal must be removed from each succeeding row of teeth. The errors are usually in profile and lead, as the hob profile can be changed from its true position by exposing the cutting edge to a different plane. The hob accuracy can be affected during the sharpening process by errors in the rake angle, flute lead, and indexing. All standard hobs are designed with a generating profile (basic rack) that defines the pressure angle, the fillet radius, addendum and dedendum, and modifications to assist following operations such as shaving and grinding, etc. It is essential to inspect the hob after sharpening.

Hobs are form-relieved cutters, sharpened by grinding the faces of the hobs teeth to the bottom of the flute, and errors frequently arise after the hob has been sharpenedusually in the profile and lead.Cutting teethThere are two popular methods used to cut the teeth: generating, and by using a formed cutter. Two designs of cutter are used are either a rotary type or a planer type tool. Using the formed rotary cutter, one tooth space at a time is cut, leaving a gap the same shape as the cutter. The most complex and costly tools used for metal cutting are those that are used for cutting teeth, particularly form cutters. Coatings are successfully used to improve tooling economics by increasing the time between sharpenings, and by keeping most of the heat away from the substrate material. Coatings for shaper cutters and hobs have been in widespread use since 1980. The latest hob technology is to use coated carbides or high-speed steels. The thin ultra-hard film increases the tools abrasion resistance and reduces tool-part adhesion. The first coating to find general use was the gold colored titanium nitride (TiN). An estimated increase in tool life of 200-300 percent is considered conservative. The better the surface before the coating is applied, the better the overall results.

ABOuT THE AuTHOr: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.

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ive explained in previous columns a few basic tenants of endo and low pressure carburizing processes, so perhaps a discussion of the equipment used in each is in order. Atmosphere carburizing with endothermic gas, in-situ gas such as LPG (liquefied petroleum gas and air), and nitrogen-methanol utilize refractory lined furnaces typically insulated with ceramic fiber or insulating fire brick (IFB). These furnaces fall under the broad category of hot walled furnaces; devices that are warm or hot to the touch. Ninety-five percent of all heat treating is performed in this type of equipment. Vacuum furnaces, cold wall vessels with water jackets, require a chamber capable of being evacuated to pressures approximating 0.0001 of an atmosphere. Your local weather forecast in the U.S. likely reports barometric pressure in inches or millimeters of mercury. This means atmospheric pressure at sea level can be stated as 14.7 psi, 30 inches of mercury, and 760 mm of mercury. A developing low pressure weather system may be reported as 29 inches or 735 mm of mercury. In metric terms pressure is referenced in bar, one bar = atmospheric pressure and for accuracy 1013 millibar equal one atmosphere. For LPC to work properly a vacuum vessel starting out at atmospheric pressure, 1013 millibar must have the air removed by a vacuum pump so that only 0.1013 millibar remain, (99.9999 percent) of the air is removed. In scientific terms 1 x 10-4 millibar. Atmospheric pressure on the moons surface is 1 x 10-11 millibar. Dont confuse barometric pressure with gravity; some think removing that much air will allow parts to float around within the vacuum vessel. Gravity is the force that keeps our feet on the ground; atmospheric pressure allows us to breathe. As indicated above, IFB insulated furnaces are used in endo carburizing. However, vacuum furnaces employing LPC are primarily insulated with only two or three inches of rigid graphite board or graphite felt. Since oxygen has been removed graphite (carbon) wont burn as it would in air, and since the pressure is very low, heat transfer to the steel vessel wall is low as well but the cold side of the graphite insulation is still very hot generally about 400F to 700F. Thus, almost all vacuum furnaces have water-cooled casings. Commercial vacuum furnaces began as single chamber devices in the late 1950s with a 0.032 inch thick molybdenum metal hot face and a few inches of ceramic fiber insulation, since ceramic fiber was in use in atmosphere furnaces and

HOTSeatDirector of process and developmental engineering, AFC-Holcroft

jacktitus

In this installment of his column the author presents a discussion of the equipment used in the endo and low pressure carburizing processes.

graphite insulation was not yet invented. Heating elements now made from graphite were in 1950 made from tungsten or molybdenum rod. Vacuum furnaces continued to evolve retaining a gap between the insulated hot zone and the water-cooled casing. This design attribute subsequently becomes a maintenance issue in LPC. Then, in about the mid-seventies, in an effort to duplicate the integral quench batch atmosphere furnace, multi-chamber vacuum furnaces began to appear. Initially vacuum furnaces were primarily used for annealing and hardening small high-speed tools such as drill bits. One may wonder why, with atmosphere furnaces requiring 13 inches of insulation, a vacuum furnace has only a few inches when they can operate a much higher temperature. The reasons, I speculate, are twofold: he very first R&D vacuum systems consisted of a tabletop mounted bell T jar and vacuum pump located beneath, and when someone had the idea of adding heat the most practical solution was a heated box inside of the jar and the space between the jar and box for wiring; s vacuum furnaces evolved and cooling was added to single chamber A furnaces in an effort to force cool the parts as fast as possible, it became necessary to reduce the heat stored in the insulation; solutionreduce the thickness. Since heat transfer in vacuum is significantly less than at one atmosphere it worked, to a degree. No pun intended. In the U.S., except for a few locations atmosphere furnaces are heated with natural gas fired radiant U tubes. Vacuum furnaces designed for traditional hardening and LPC due to the hot zone/inner chamber construction and because of higher operating temperature most often have resistance heated graphite elements. Vacuum, having effectively very few gas molecules, has very little resistance to high voltage jumping across a small space resulting in an arc, therefore the (secondary) electrical power connected to the heating elements must be limited to 80 volts AC, 60 Hz. LPC having acetylene gas thus the potential for soot (carbon) that is electrically conductive must limit the power to 24 volts AC. Next month, more on furnace construction and types of heat treat equipment.

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

JUNE 2011

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COMPANY PROF ILE

JLM Systems, Ltd.Developer of oiLMiSeR technologies, this company provides clean and efficient fluid handling devices to customers found around the world.By Russ Willcutt

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Whats the recipe for creating an innovator? In the case of Dick Gangnon you take one part engineer, with their dedica tion to creating efficient systems; a smidgeon of the inven tor, whos always dreaming up better ways of doing things; and a dash of the entrepreneur, who is willing to take risks and harness new technologies. My background is in industrial engineering, so efficiency is what its all about, says Gangnon, who is president of JLM Systems and developer of OILMISER technologies. I began my career back in the mid-sixties in the wire rope business, where I started learning about lubricants, and then I went into hydraulics as a technical sales representa tive for several companies. In those days, when the price of hydraulic fluid was about 27 cents a gallon, people werent concerned about conserving it. The system reservoirs were huge, and when it was time to change the fluid youd just discard it. That changed in the seventies, when the price rose to more than a dollar a gallon and certain environmental regulations were introduced, and suddenly everyone wanted smaller reservoirs on their hydraulic systems for less fluid usage. In smaller quantities, the contaminants common in fluids at that time as a result of improper handling became concentrated, slashing equipment uptime. People werent careful with their lubricants back then, Gangnon recalls. It would arrive in 55 gallon drums, and they would simply pour it into whatever bucket was available to transfer it to the machines. And when youre talking about sawmills or mining operations, its a very dirty environment, so the oil and the receptacles that held it were just filthy. It was readily apparent to me that this contamination was responsible for the vast majority of equipment breakdown and downtime they were experiencing, so I decided to do something about it. His solution was the OILMISER FILLorDRAIN, which effectively closed the loop on airborne contamination between the drum and reservoir. He established JLM Systems to manufacture the device, which he sold through the companies he represented as an outside salesman. The success of the FILLorDRAIN motivated him to consider other challenges he could help his customers overcome, and he continued launching new products as a sideline venture. He also continued broadening his experience, eventually becoming director of hydraulic operations for a large industrial supplier. Then a technology made its appearance that changed everything for him. Its called the Internet, Gangnon says with a laugh. As it grew in popularity I realized it represented a way for me to eliminate the middlemanwholesale industrial suppliers, in my case, who werent that interested in taking on new linesand sell directly to the end user. So thats what I decided to do.

After taking classes to learn about the Internet and Web-site design, Gangnon began devoting all his energy to JLM Systems in the late nineties, introducing the products hed been dreaming up in quick succession. In 2000 he launched a modified FILLorDRAIN for oil sampling, then an offline filtration kit featuring a kidney-loop design in 2003 and a color-coded filtration system the following year. The OILMISER Vapor Guard appeared in 2004, and soon sample tubes, reservoir aspirators, and sampling plugs and valves came on the scene. Today the companys Web site features a wide selection of devices, supplies, and accessories that can be purchased directly or through a network of approved resellers. Just as the advent of the Internet enabled the launch of his company, it continues to play a major role in how it operates. In addition to speaking on the subject to various companies that bring him in to educate to their employees, Gangnon communicates with end-users all around the world who send him photos of their machines and systems so that he can suggest OILMISER devices that will meet their requirements. At this point all I need to see is a picture of their setup, ask a couple of questions, and I can tell them exactly what they need, he says, and Ill either sell it to them directly or to their preferred local vendor. Gangnon has seen many changes over the years, including the elevation of a job once referred to simply as maintenance to a highly specialized field made up of reliability engineers and technicians, with their own set of professional certifications. As for what motivates him today, he says his goal remains unchanged. When you encounter inefficiency, its likely to stay that way until somebody does something about it, he says. And when it comes to hydraulic systems, that somebody is me!

TO LEArN MOrE:Call (888) 736-8645 or (604) 521-3248, e-mail info@oilmiser.com, or visit online at [www.oilmiser.com].

Refurbishing Wind Turbine GearsIsotropic superfinishing represents a value adding, low cost option for refurbishing both case carburized and nitrided gears.By Mark Michaud, Gary J. Sroka, and Ronald E. Benson

MWear is greatest on the input stage, especially on the sun pinion gear. Historically, grinding is utilized to refurbish these damaged gears. There including but not limited to high capital investment and the extraordinary amount of time and skill involved in are numerous drawbacks, however, the grinding process. Moreover, nitrided gears cannot be ground and must be scrapped. However, chemically

MULTI-MEGAWATT WIND TURBINE GEARBOXES OPERATE UNDER DEMANDING ENVIRONMENTAL CONDITIONS INCLUDING CONSIDERABLE VARIATION IN TEMPERATURE, WIND SPEED, AND AIR QUALITY. IT IS NOT QUALITY A FEW YEARS. THESE GEARBOXES EXPERIENCE SEVERAL TYPES OF REPAIRABLE DAMAGE INCLUDING

UNCOMMON FOR GEARBOXES RATED FOR A MAINTENANCE FREE 20-YEAR LIFESPAN TO FAIL AFTER ONLY 20MICROPITTING OR GRAY STAINING, ABRASIVE WEAR, FOREIGN OBJECT DEBRIS (FOD) DAMAGE, SURFACE

CORROSION, AND FRETTING CORROSION.accelerated vibratory finishing, or isotropic superfinishing (ISF), represents a value adding, low-cost option for refurbishing both case carburized and nitrided gears. Isotropic superfinishing removes light to moderate gear flank surface damage. The result is a surface with a non-directional pattern with a roughness of approximately 0.08 mm or less. Moreover, evidence suggests that isotropic superfinishing imparts a finish that increases gear durability and service life in the field. A case study on a sun pinion gear is presented.

introDuCtionTypical multiple megawatt (MW) gearboxes, 1.5 MW and higher, are designed to operate for 20 years without requiring major maintenance to the drive train. However, many owners

Fig. 1: Micropitting or gray staining on gear flanks (a), heavy abrasive wear on gear flank and a SEM image of trail left by an abrading particle (b) [4], a foreign object debris (FOD) damage (c), corrosion looking down on top land (d) [4], and fretting corrosion (e). JUNE 2011 29b d a

c

e

are experiencing gearbox failures after only a few years of service. Gearbox repairs may cost $360,000 (USD) or more for a complete replacement by 2009 estimates [1]. Gears fail for several reasons. Wind turbine gears operate under extreme environmental conditions including highly variable temperature, wind speeds, and air quality. These conditions cause variable high loading and torque. During periods of low or no wind, the loading on slowly moving or stationary gears is exacerbated. Moreover, moisture can contaminate the lubricant and condense on the gear surfaces forming sludge, corrosion and micropitting. Finally, dust and other foreign debris in the air can contaminate the lubricant during maintenance, leading to abrasive wear. Fortunately condition monitoring systems allow gearbox prob-

Fig. 3: Ground surface (top) vs. an isotropic superfinish surface (bottom).

Fig. 2: The superfinishing process.

Fig. 4: A crack on a used gear near the addendum of the tooth was revealed only after superfinishing.

Fig. 5: Graphite tape lifts from damaged gear surface before (top) and after (bottom) superfinishing refurbishment. 30 gearsolutions.com

lems to be discovered before serious gear damage occurs [2, 3].

cesshenceforward referred to as superfinishingis an alternative time and cost efficient method of gear refurbishment. The process utilizes conventional vibratory finishing equipment and high density, nonabrasive finishing media to produce isotropic surface finishes with a final surface roughness (Ra) below 0.10 mm. The superfinishing process is easily understood by referring to fig. 2. At the start of the superfinishing process shown in step 1 of fig. 2, the original metal surface reacts a first time with the active chemistry, forming the first conversion coating (step 2) [8]. The vibratory machine and nonabrasive media produce an effective rubbing motion on the surface of the gear (step 3). This exposes the peak asperities of the metal surfaces to a second reaction (step 4), reforming the complete conversion coating. The process of conversion coating reformation and removal (step 5) is continued through many successive cycles, thus planarizing

the original rough machined or damaged surface. The final required surface finish governs the total number of cycles. This planarizing process is continued until the gears are smoothed to the required surface finish quality. Once the required surface finish quality is achieved, the active chemistry from the smoothing stage of the superfinishing process is drained away and a neutral, burnishing soap is introduced into the vibratory machine. The burnish removes all remaining conversion coating (step 6) from the surface of the gear, producing a mirrorlike appearance while imparting a mild rust preventive to the surface. The gear is ready for unloading and the superfinishing process is complete. Figure 3 shows a comparison of a ground gear surface versus a superfinished gear surface. The initial selection of the proper media shape, size, and mixture is a significant part of the art to successfully superfinishing gears. Media is specifically cho-

bACkgrounDAs mentioned, wind turbine gears experience several types of repairable damage including micropitting or gray staining, abrasive wear, foreign object damage (FOD), surface corrosion, and fretting corrosion. An example of each is depicted in fig. 1 [4, 5]. There are three main approaches to repairing gear damage: refurbishment by regrinding, refurbishment by surface finishing, or replacement with a new gear. The refurbishment process is a combination of reclamation and reconditioning of a used gear or bearing [6]. New gearing is expensive, which makes surface finishing and regrinding the preferred low-cost alternatives. Regrinding is necessary when lead and profile corrections are required on the working surfaces of the gear teeth [7]. The Isotropic Superfinish, or ISF pro-

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sen based on the following criteria: root diameter, diametral pitch, gear size, gear mass, and alloy. Once the media is chosen, the superfinishing process repeatedly finishes gears identically. The media is nonabrasive, and therefore has a very low attrition rate. The size, shape, and density of the media remain stable over thousands of hours of vibratory machine

a

operation. The superfinishing process possesses several ideal features. uperfinishingremovesmetaluniformly S from every tooth of the gear with the ability to control total stock removal down to below 2.50 mm; hereisnodiscolorationortemperburn, T a risk that is associated with grinding; uperfinishingdoesnotdestroyresidual S compressive stress surface layers [9].

b

Residual compressive stress is imparted on the surface during case hardening. Compressive stress slows the rate of surface wear and inhibits corrosion [10]. Hence, the superfinished gear exhibits a superior surface versus used gears that are refurbished by grinding; heprocessworksonnitridedaswellas T case carburized surfaces; he superfinishing process is an ideal T technique for improving the inspection

c Fig. 6: Surface trace of a new ground low-speed stage pinion before superfinishing: 2282 (a), of a used low-speed stage pinion before superfinishing: 2308 (b), and after superfinishing: 2282 (c).

of refurbished gears. There is sufficient material removal to reveal subsurface damage from micropitting, scuffing and corrosion that may be masked by the texture of the used surface. Grinding

a

b

Fig. 7: Superfinished intermediate gear assembly (a), characteristic Isotropic Superfinish on the flanks of the same assembly (b): photos courtesy Moventas. JUNE 2011 33

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a

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Fig. 8: Sun pinion gear with several modes of damage including hard line micropitting (a), and the same gear after refurbishment (b).and in-service wear may cause a smearing of the metal on the gear surface resulting in subsurface damage not only being invisible to the naked eye, but also potentially going undetected by other inspection methods [11]. For example, fig. 4 depicts a cracked gear tooth that was delivered by a customer and deemed suitable for refurbishment. Only after superfinishing did the crack become visible. Consequently, this gear was scrapped and the potential catastrophic failure of the gearbox was avoided. In general, superfinishing can; uperfinishingcanalsoremovelight(I 25 Km depth) to modS erate (130 mm depth) damage from the gear tooth surface while maintaining geometric tolerances. Figure 5 shows images of the graphite tape lift method that is used to measure and record the amount of micropitting on a gear flank [12]. The deepest micropitting damage is approximately 150 mm (see arrows). In this instance, it is apparent that some

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micropitting remains after superfinishing. The removal of all damage may have compromised the geometry of the gear. However, the peak asperities or stress raisers were removed and the existing micropitting will, in all likelihood, not progress to pitting and eventual spalling [13]. Recently, gearbox manufacturers indicated between 150-250 mm can be safely removed without compromising gear geometry (maximum removal amount is per customer specifications). Gear refurbishment via superfinishing was evaluated for bending fatigue, contact fatigue, and scoring resistance tests on military helicopter gears by the Gear Research Institute (GRI) [14, 15]. Importantly, GRI results suggest that in all three tests, the repaired gears met or exceeded the performance of the new gears. Figure 6 depicts profilometer traces of (a) new ground gear, (b) used gear prior to refurbishment, and (c) used gear after refurbishment via superfinishing. Superfinishing has several distinct advantages over regrinding in terms of time and cost savings. First, the process does not require engineering drawings. Second, all teeth are uniformly and simultaneously finished. For example, the cost per tooth is the same for a small gear with 59 teeth versus a large gear with 113 teeth. Third, as described superfinishing requires less setup time and potential complications versus grinding. Consequently, the turnaround time is rapid. Fourth, typically the ring, sun, and pinion gears of the low-speed stage and the output pinions of the high-speed stage receive the most wear and are refurbished. However, the gears of the intermediate stage, especially an assembled intermediate unit, also can be superfinished with little additional expense since the entire gearbox is removed for maintenance. Figure 7 depicts a refurbished assembled intermediate stage gear.

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CAse stuDyA case study was performed on the input stage of a 1.5 MW wind turbine gearbox. The low-speed sun pinion gear usually shows the most damage and will be used here to describe the superfinishing refurbishment process. It should be noted that customers frequently request complete refurbishment of the planetary gears and hollow wheel gear as well. The sun pinion gear is shown in figs. 8a and b. The following protocol was used to refurbish this pinion gear: 1) After the gear was received it was inspected for damage. Micropitting and light abrasive wear were noted. Pre-finishing inspection is crucial as gears may be damaged during decommissioning and/or transport; 2) The initial average surface roughness (Ra) was measured to

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be 0.31 mm (refer to Table 1); 3) The gear was placed in a vibratory finishing apparatus with an optimized media mixture to effect uniform stock removal on the flank; 4) It was processed in active chemistry for a short duration and then carefully inspected for hidden serious damage such as cracks or deep pitting. No seri-

ous damage was detected; 5) The gear was further processed in active chemistry and its surface roughness was periodically monitored with a skidded portable profilometer until the targeted Ra was achieved (a Hommel T1000 Basic with a skidded T1E probe and a 5 mm stylus was used for the case study, with the profilometer cali-

brated to ISO 5436 standard); 6) The pinion was then burnished to remove all traces of the conversion coating; 7) The Ra of the superfinished refurbished gear was determined to be 0.07 mm (refer to Table 2).

resuLts AnD DisCussionIn the case study discussed, the planet and hollow wheel (ring) gears were also successfully refurbished. Customers utilize CMM to determine if the gears are still within tolerances after the parts are returned. All gearswith more than 2300 refurbished to dateremain within the required tolerance. In the majority of cases, all traces of micropitting and other moderate tooth damage can be successfully removed with superfinishing. Even if the micropitting is too deep to remove completely, the peak asperities or stress raisers are removed and micropitting will not progress to pitting and eventual spalling. Moreover, superfinishing will remove the raised lip around the lip of a FOD dent even if the valley of the damaged area is not completely removed. Gears with severe subsurface micropitting or in need of tooth profile correction must be reground first. However, it is still advantageous to use superfinishing as the final step in order to impart a much longer service life. Ongoing field tests, now more than two years old, are being conducted to corroborate that superfinished wind turbine gears have equivalent or superior performance versus new ground gears. Currently, refurbishing wind turbine gears via superfinishing is in commercial operation as a viable replacement to regrinding by a major wind turbine gearbox manufacturer.

ConCLusionsIn terms of time, cost, and in-service performance superfinishing has several distinct advantages. The majority of damage sustained on in-service gears in wind turbine gearboxes can be successfully refurbished by superfinishing. Superfinishing is time efficient and economical since all teeth are finished simultaneously versus a few teeth

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Table 1: Ra and Rz measurements taken at different locations on the sun pinion prior to refurbishment.

Table 2: Four Ra and Rz measurements taken at different locations on the sun pinion after refurbishment.

at a time, large gears finish in the same amount of time as small gears, proprietary drawings or expensive reverse engineering is not required, and nital etch inspection is unnecessary. Also, the equipment is inexpensive when compared to regrinding, and setup is simple and does not require extensive operator training. Typically the ring, sun, and pinion gears of the low-speed stage and the pinion gears of the high-speed stage that acquire the most wear are refurbished. However, the gears of the intermediate and assembled intermediate stage can be refinished with little additional expense since the entire gearbox must be removed for maintenance. Also, superfinishing can reveal pre-existing subsurface damage concealed by grinding or in-service wear related smearing. Previous studies by independent sources indicate that refurbishment of used gears by superfinishing results in extended operational life and reduced maintenance costs. And finally, when regrinding may be the only way to remove the deep damage and reshape tooth geometry, superfinishing afterward will result in more-durable surfaces and, hence, a gearbox with greater longevity in the field.

STLE 65th Annual Meeting and Exhibition Wind Turbine Tribology I, May 2010. 3) Juggling with Failure as an Option, Windpower Monthly News Magazine, May 2008. www.windpower-monthly.com 4) Errichello, R., Technical Training Seminars: Gear Failure Analysis, American Gear Manufacturers Association, 2007. 5) Franke, J.-B., Grzybowski, R., Lifetime Prediction of Gear Teeth Regarding to Micropitting in Consideration of WEC Operating States. Presented at DEWEK 2004: The International Technical Wind Energy Conference. 6) Flowers, K., Bearing Repair Provides Valuable Alternative to Bearing Replacement for Heavy Industries, Iron & Steel Technology, 2009, 6 (6), 85-89. 7) Schmid, R., Process for the Modification of Tooth Traces and/or for the Correction of Tooth Trace Deviations of a Gear, United States Patent 6,752,695 B2, May 22, 2004. 8) Arvin, J., Manesh, A., Michaud, M., Sroka, G., Winkelmann, L., The Effect of Chemically Accelerated Vibratory Finishing on Gear Metrology, American Gear Manufacturers Association, 2002. 9) Dini, J.W., Fundamentals of Chemical Milling, Am. Mach., 1984, 128, 113128. 10) Lynwander, P., Gear Drives Systems, Marcel Dekker: New York, 1983. 11) Astakhov, V. P., Surface Integrity in Machining, Ed. J. P. Davim. Springer: 2010; pp. 1-35.

12) McNiff,

B.,

Errichello,

Musial,W.,

Documenting the Progression of Gear Micropitting in the NREL Dynamometer Test Facility, AWEA, 2002. 13) Michaud, M., Summers, E., Superfinishing Large Planetary Gear Systems, European Patent EP1646477, April 29, 2009. 14) Rao, Suren B., Repair of CH-46 Helicopter Gears, Journal of the Reliability Information Analysis Center, First quarter, 2007. 15) Rao, S., McPherson, D., Sroka, G., Repair of Helicopter Gears, American Gear Manufacturers Association, 2005.

ABOuT THE AuTHOrS:Mark Michaud is with REM Surface Engineering, and Gary J. Sroka and Ronald E. Benson are with the REM Research Group. Visit online at [www.remchem.com].

referenCes:1) Proactive Service Pays Dividends, Windpower Monthly News Magazine (Supplement), Ma